warning YAMAHA XT660R 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU21380
Adjusting the throttle cable
free play The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21640
TiresTo maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10500


The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
1. Throttle cable free play
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Fr o nt :
XT660R 200 kPa (29 psi) (2.00
kgf/cm²)
XT660X 210 kPa (30 psi) (2.10
kgf/cm²)
Rear:
XT660R 200 kPa (29 psi) (2.00
kgf/cm²)
XT660X 210 kPa (30 psi) (2.10
kgf/cm²)
90–186 kg (198–410 lb):
Fr o nt :
XT660R 200 kPa (29 psi) (2.00
kgf/cm²)
XT660X 220 kPa (32 psi) (2.20
kgf/cm²)
Rear:
XT660R 225 kPa (33 psi) (2.25
kgf/cm²)
XT660X 230 kPa (33 psi) (2.30
kgf/cm²)
Off-road riding:
Fr o nt :
XT660R 200 kPa (29 psi) (2.00
kgf/cm²)
Rear:
XT660R 200 kPa (29 psi) (2.00
kgf/cm²)
Maximum load*:
186 kg (410 lb)
* Total weight of rider, passenger, car-
go and accessories

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
WARNING
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.

NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


Check the tire condition and airpressure before each ride.
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
Tire information
This motorcycle is equipped with tube
tires.
WARNING
EWA10460


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model byYamaha Motor Co., Ltd.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
WARNING
EWA10570


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to aYamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
EAU21940
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
Front tire:
Size:
XT660R 90/90-21M/C 54S, 90/90-
21M/C 54T
XT660X 120/70R17 M/C 58H
Manufacturer/model:
XT660R METZELER/TOURANCE
FRONT
XT660X PIRELLI/DRAGON
XT660R MICHELIN/SIRAC
Rear tire:
Size:
XT660R 130/80-17M/C 65S,
130/80-17M/C 65T
XT660X 160/60R17 M/C 69H
Manufacturer/model:
XT660R METZELER/TOURANCE
XT660X PIRELLI/DRAGON
XT660R MICHELIN/SIRAC A

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU23100
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.
EAU23110
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU23180
Lubricating the brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU23200
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6 To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
WARNING
EWA10760


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes whenworking near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OFCHILDREN.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
CAUTION:
ECA10630


Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (constant-volt-
age) battery charger is required.
Using a conventional battery
charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charg-
er, have a Yamaha dealercharge your battery.
1. Negative battery terminal
2. Positive battery terminal
3. Bolt
4. Battery cover

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6 4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAUM1750
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove cowling A together with
the headlight unit. (See page 6-5.)
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
4. Place a new bulb into position, and
then secure it with the bulb holder.CAUTION:
ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
1. Headlight bulb cover
2. Headlight coupler
1. Headlight bulb holder
2. Headlight bulb

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
EAU24360
Front wheel
EAUM1761
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the front wheel axle pinch
bolts, then the wheel axle and the
brake caliper bolts.
XT660RXT660X
2. Lift the front wheel off the ground
according to the procedure on
page 6-33.
3. Remove the brake caliper by re-
moving the bolts.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
4. Pull the wheel axle out, and then
remove the wheel.
EAUM1811
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
1. Wheel axle
2. Front wheel axle pinch bolt A
3. Front wheel axle pinch bolt B
1. Wheel axle
2. Front wheel axle pinch bolt A
3. Front wheel axle pinch bolt B
1. Bolt
2. Brake caliper

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6 4. Install the brake caliper by install-
ing the bolts.
NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brakedisc.
5. Tighten the wheel axle to the spec-
ified torque.
6. Tighten the wheel axle pinch bolt A
and pinch bolt B to the specified
torques.
7. Retighten the wheel axle pinch bolt
A to the specified torque.
8. Tighten the brake caliper bolts to
the specified torques.
9. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAUM1771
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Remove the drive chain guard by
removing the bolts.
XT660RXT660X
2. Loosen the axle nut.
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
1. Bolt
2. Drive chain guard
1. Bolt
2. Drive chain guard
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
4. Brake caliper bracket
5. Brake caliper