air condition YAMAHA XT660R 2004 Owners Manual

SAFETY INFORMATION
1-2
1 due to EXCESSIVE SPEED or un-
dercornering (insufficient lean an-
gle for the speed).
Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.


The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.


Never ride under the influence of
alcohol or other drugs.Protective apparel
The majority of fatalities from motor-
cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre-
vention or reduction of head injuries.


Always wear an approved helmet.


Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.


The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.


Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.


Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.


Passengers should also observe
the precautions mentioned above.Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
186 kg (410 lb). When loading within
this weight limit, keep the following in
mind:

PRE-OPERATION CHECKS
4-1
4
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.NOTE:Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very shorttime; and the added safety it assures is more than worth the time involved.
WARNING
EWA11150
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operatingthe vehicle.

PRE-OPERATION CHECKS
4-3
4
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-17, 6-25
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-25
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-23, 6-24
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-17, 6-19
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-26
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-25
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-26
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-14 ITEM CHECKS PAGE

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17520
Owner’s tool kit The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-12.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
2. Engine oil drain attachment

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√
4 Air filter elementReplace.√√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAUM1710
Panel B
To remove the panel1. Remove the seat. (See page
3-12.)
2. Remove the bolt, and then pull the
panel off at the areas shown.
To install the panel1. Place the panel in the original posi-
tion, and then install the bolt.2. Install the seat.
EAU19602
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
1. Bolt
1. Spark plug cap

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
6-25
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
6-27
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.

SPECIFICATIONS
8-2
8
Operation:
Left foot operation
Gear ratio:
1st:
30/12 (2.500)
2nd:
26/16 (1.625)
3rd:
23/20 (1.150)
4th:
20/22 (0.909)
5th:
20/26 (0.769)Chassis:Frame type:
Diamond
Caster angle:
XT660R 27.25 °
XT660X 26.00 °
Trail:
XT660R 107.0 mm (4.21 in)
XT660X 94.0 mm (3.70 in)Front tire:Type:
With tube
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
Manufacturer/model:
XT660R MICHELIN/SIRAC
Rear tire:Type:
With tube
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
Manufacturer/model:
XT660R MICHELIN/SIRAC ALoading:Maximum load:
186 kg (410 lb)
(Total weight of rider, passenger, cargo and
accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0–198 lb)
Front:
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)
Loading condition:
90–186 kg (198–410 lb)
Front:
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:
Front:
XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
Rear:
XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
Front wheel:Wheel type:
Spoke wheel
Rim size:
XT660R 21x1.85
XT660X 17M/C x MT3.50Rear wheel:Wheel type:
Spoke wheel
Rim size:
XT660R 17M/C x MT2.75
XT660X 17M/C x MT4.25Front brake:Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4