clutch YAMAHA XT660X 2008 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2008, Model line: XT660X, Model: YAMAHA XT660X 2008Pages: 92, PDF Size: 5.05 MB
Page 40 of 92
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
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Page 50 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
68. Remove and replace the oil filter
element and O-rings.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. In
1. Oil filter element cover bolt
2. Oil filter element drain bolt
1. Oil filter element
2. O-ring
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)
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Page 59 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
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.
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.
1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
1. Locknut
2. Clutch lever free play adjusting nut (crank-
case)
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Page 60 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
65. 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.
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 wear
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove
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Page 65 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
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.
EAU23111
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 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
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Page 84 of 92
SPECIFICATIONS
8-1
8
Dimensions:Overall length:
XT660R 2240 mm (88.2 in)
XT660X 2175 mm (85.6 in)
Overall width:
XT660R 845 mm (33.3 in)
XT660X 860 mm (33.9 in)
Overall height:
XT660R 1230 mm (48.4 in)
XT660X 1170 mm (46.1 in)
Seat height:
XT660R 865 mm (34.1 in)
XT660X 875 mm (34.4 in)
Wheelbase:
XT660R 1505 mm (59.3 in)
XT660X 1490 mm (58.7 in)
Ground clearance:
XT660R 210 mm (8.27 in)
XT660X 205 mm (8.07 in)
Minimum turning radius:
2400 mm (94.5 in)Weight:With oil and fuel:
XT660R 181.0 kg (399 lb)
XT660X 186.0 kg (410 lb)Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
660.0 cm³
Bore × stroke:
100.0 × 84.0 mm (3.94 × 3.31 in)Compression ratio:
10.00 :1
Starting system:
Electric starter
Lubrication system:
Dry sump
Engine oil:Type:
SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element replacement:
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)Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator capacity (including all routes):
1.00 L (1.06 US qt) (0.88 Imp.qt)
Air filter:Air filter element:
Oil-coated paper elementFuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
15.0 L (3.96 US gal) (3.30 Imp.gal)
Fuel reserve amount:
5.0 L (1.32 US gal) (1.10 Imp.gal)Fuel injector:Manufacturer:
DENSO
Model/quantity:
297500-0390Spark plug (s):Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
75/36 (2.083)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
45/15 (3.000)
Transmission type:
Constant mesh 5-speed
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
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Page 89 of 92
INDEX
AAir filter element and check hose,
replacing and cleaning ....................... 6-16
Anti-theft alarm (optional) ....................... 3-7
Auxiliary light bulb, replacing ................ 6-35BBattery .................................................. 6-30
Brake and clutch levers, checking and
lubricating ........................................... 6-27
Brake fluid level, checking .................... 6-23
Brake lever ............................................. 3-9
Brake pedal .......................................... 3-10
Brake pedal, lubricating ........................ 6-28CCables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converter ................................ 3-12
Clutch lever............................................. 3-9
Clutch lever free play, adjusting ........... 6-21
Coolant ................................................. 6-13
Coolant temperature warning light.......... 3-4
Cowlings and panels, removing and
installing ............................................... 6-5DDimmer switch ........................................ 3-8
Drive chain, cleaning and lubricating .... 6-26
Drive chain slack .................................. 6-24EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-17
Engine oil and oil filter element............. 6-10
Engine stop switch.................................. 3-8
Engine trouble warning light ................... 3-4
FFront and rear brake pads, checking .... 6-22
Front fork, checking...............................6-29
Fuel ....................................................... 3-11
Fuel consumption, tips for reducing ........ 5-3
Fuel level warning light............................ 3-4
Fuel tank cap......................................... 3-10
Fuses, replacing .................................... 6-32HHandlebar switches ................................. 3-7
Hazard switch.......................................... 3-8
Headlight bulb, replacing....................... 6-33
High beam indicator light......................... 3-4
Horn switch ............................................. 3-8IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-15
Immobilizer system .................................3-1
Immobilizer system indicator light ........... 3-4
Indicator and warning lights .................... 3-3KKey identification number ........................ 9-1MMain switch/steering lock ........................ 3-2
Model label .............................................. 9-2
Multi-function display...............................3-5NNeutral indicator light .............................. 3-3PParking ....................................................5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-8
Periodic maintenance and lubrication
chart ......................................................6-2Pre-operation check list .......................... 4-2
RRear brake light switch, adjusting ......... 6-22SSafety information ................................... 1-1
Seat ...................................................... 3-12
Shifting .................................................... 5-2
Shift pedal ............................................... 3-9
Shock absorber assembly, adjusting .... 3-13
Sidestand .............................................. 3-14
Sidestand, checking and lubricating ..... 6-28
Spark plug, checking .............................. 6-9
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ............................................. 3-8
Steering, checking ................................ 6-29
Storage ................................................... 7-3
Storage compartment ........................... 3-13
Supporting the motorcycle .................... 6-35TThrottle cable free play, checking ......... 6-18
Throttle grip and cable, checking and
lubricating ........................................... 6-27
Tires ...................................................... 6-18
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-39
Troubleshooting charts ......................... 6-40
Turn signal indicator light ........................ 3-3
Turn signal light bulb or tail/brake light
bulb, replacing .................................... 6-34
Turn signal switch ................................... 3-8VVehicle identification number .................. 9-1
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