turn YAMAHA XT660R 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
62. Place the cowling in the original
position, and then install the bolts
and spacers.
EAUM1691
Cowling B
To remove the cowling1. Remove the seat and panel B.
(See pages 3-12 and 6-5.)
2. Remove the bolts, remove the
quick fastener screws after turning
them 1/4 turn counterclockwise,
and then pull the cowling off at the
area shown.To install the cowling
1. Place the cowling in the original
position, and then tighten the quick
fastener screws and install the
bolts.
2. Install the panel.
3. Install the seat.
EAUM1701
Panel A
To remove the panel1. Remove the seat. (See page
3-12.)
2. Remove the bolts and the spacer,
and then pull the panel off at the
area shown.To install the panel
1. Place the panel in the original posi-
tion, install spacer, and then install
the bolts.
2. Install the seat.
1. Bolt
2. Quick fastener screw
1. Bolt
2. Spacer

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have aYamaha dealer check the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
1. Spark plug wrench
Specified spark plug:
NGK/CR7E1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAUM1841
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for 10–
15 minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:

The engine oil tank is located in-
side of the frame.


The engine oil should be between
the minimum and maximum levelmarks.
CAUTION:
ECA10010
Do not operate the vehicle until you
know that the engine oil level is suf-ficient.
WARNING
EWA10360
Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oiltank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Install the engine oil drain attach-
ment, provided with the owner’s
tool kit, under the drain bolt of the
crankcase.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6 9. Install the oil filter element cover by
installing the bolts and the oil filter
element drain bolt, then tightening
them to the specified torques.
NOTE:Make sure that the O-rings are properlyseated.
10. Install the oil drain bolts, and then
tighten them to the specified
torques.
11. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
ECAM1060
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt) of
the recommended engine oil. Then,
start the engine, race it 5 or 6 times,
turn it off, and then add the remain-der of the engine oil.CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. Inaddition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
12. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
13. Turn the engine off, and then
check the oil level and correct it if
necessary.
Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt (crankcase):
30 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank):
18 Nm (1.8 m·kgf, 13 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
2.50 L (2.64 US qt) (2.20 Imp.qt)
With oil filter element replacement:
2.60 L (2.75 US qt) (2.29 Imp.qt)

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
6-16
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
6-20
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
6-23
6
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22780
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.NOTE:When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there shouldbe no weight on it.
2. Shift the transmission into the neu-
tral position.3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
4. If the drive chain slack is incorrect,
adjust it as follows.
NOTE:When checking the drive chain slack,
the chain tensioner should not betouching the drive chain.
EAU22930
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-sition for proper wheel alignment.CAUTION:
ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within thespecified limits.
1. Drive chain slack
Drive chain slack:
40.0–55.0 mm (1.57–2.17 in)
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
4. Alignment marks