YAMAHA XT660R 2004 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
NOTE:

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page6-38 for further instructions.
EAUM1801
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.
2. Remove the seat and panel B.
(See pages 3-12 and 6-5.)
3. Remove cowling B. (See page
6-5.)
4. Place a container under the engine
to collect the used coolant.
5. Loosen the radiator cap retainer
screw.
6. Remove the radiator cap and cool-
ant reservoir cap.
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.7. Remove the coolant reservoir
bolts, and then turn the coolant
reservoir upside down to empty it.
8. Install the coolant reservoir by
placing it in the original position,
then installing the bolts.9. Remove the coolant drain bolt to
drain the cooling system.
10. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
1. Radiator cap
2. Radiator cap retaining screw
3. Radiator cap retainer
4. Coolant reservoir cap
1. Bolt
1. Coolant drain bolt

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
611. Install the coolant drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.
12. Pour the specified amount of rec-
ommended coolant into the radia-
tor and reservoir.
CAUTION:
ECA10470


If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.
13. Install the coolant reservoir cap.
14. Install the radiator cap and radiator
cap retainer by installing the
screw.
15. Start the engine, let it idle for sev-
eral minutes, and then turn it off.16. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
17. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
18. Install the cowling, the panel and
the seat.
Tightening torque:
Coolant drain bolt:
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol anti-
freeze containing corrosion inhibitors
for aluminum engines
Coolant quantity:
Radiator capacity (including all
routes):
1.00 L (1.06 US qt) (0.88 Imp.qt)
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAUM1833
Replacing the air filter element
and cleaning the check hose The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if neces-
sary.
To replace the air filter element
1. Remove the seat. (See page
3-12.)
2. Remove panel B. (See page 6-5.)
3. Remove the air filter case cover by
removing the screws.4. Pull the air filter element out.
5. Insert a new air filter element into
the air filter case as shown.
CAUTION:
ECA10480


Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
6. Install the air filter case cover by in-
stalling the screws.
7. Install the panel.
8. Install the seat.
To clean the air filter check hose
1. Check the hose on the side of the
air filter case for accumulated dirt
or water.
1. Air filter case cover
2. Screw
1. Air filter element

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
62. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAUM1910
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.NOTE:

The engine is warm when it quickly
responds to the throttle.


A diagnostic tachometer is neededto make this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the idle adjust-
ing screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
NOTE:
If the specified idling speed cannot be
obtained as described above, have aYamaha dealer make the adjustment.
1. Air filter check hose
1. Idle adjusting screwEngine idling speed:
1300–1500 r/min

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
6-20
6
EAU22041
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
NOTE:If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed asfollows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
4. Loosen the locknut at the crank-
case.5. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
ver free play, turn the adjusting nut
in direction (b).
6. Tighten the locknut at the clutch le-
ver and the crankcase.
1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
1. Locknut
2. Clutch lever free play adjusting nut
(crankcase)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU22270
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove
1. Lining thickness

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU22580
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4