brake YAMAHA XT660X 2008 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6XT660X
3. Lift the rear wheel off the ground
according to the procedure on
page 6-35.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing nuts (or bolts according to the
model) fully in direction (a).
6. Remove the wheel axle by remov-
ing the axle nut.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain cannot be disassem-bled.
8. Pull the wheel backward and move
the brake caliper away from the
wheel.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.
EAUM2140
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Install the wheel, the washer(s)
and the brake caliper bracket by
inserting the wheel axle from the
left-hand side.NOTE:

XT660R: Install the washer with
the “N” mark on the right-hand side
and the washer with the “O” mark
on the left-hand side. Be sure to in-
stall both washers with their marks
facing outward.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper bracket
5. Brake caliper
3
1245(a)
1. Brake caliper
2. Brake disc
U5VKE1E0.book Page 38 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6


XT660X: Install the washer on the
right-hand side.


Make sure that the retainer on the
swingarm is inserted into the slot in
the brake caliper bracket.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.
3. Lower the rear wheel so that it is
on the ground.
4. Adjust the drive chain slack. (See
page 6-24.)
5. Tighten the axle nut to the speci-
fied torque.6. Install the drive chain guard by in-
stalling the bolts.
EAU25870
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Retainer
2. Slot
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
U5VKE1E0.book Page 39 Tuesday, July 18, 2006 1:00 PM

MOTORCYCLE CARE AND STORAGE
7-1
7
EAU26001
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10770


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound afterwashing.
U5VKE1E0.book Page 1 Tuesday, July 18, 2006 1:00 PM

MOTORCYCLE CARE AND STORAGE
7-2
7 After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:Salt sprayed on roads in the winter mayremain well into spring.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of thesalt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA11130


Make sure that there is no oil or
wax on the brakes or tires.


If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-nering behavior.
CAUTION:
ECA10800


Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
U5VKE1E0.book Page 2 Tuesday, July 18, 2006 1:00 PM

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,
120/70ZR17 M/C 58W,
120/70ZR17 M/C 58WManufacturer/model:
XT660R METZELER/TOURANCE
FRONT,
MICHELIN/SIRAC
XT660X PIRELLI/DRAGON,
METZELER/SPORTEC M1,
MICHELIN/RADIAL PILOT SPORT
Rear tire:Type:
With tube
Size:
XT660R 130/80-17M/C 65S,
130/80-17M/C 65T
XT660X 160/60R17 M/C 69H,
160/60ZR17 M/C 69W,
160/60ZR17 M/C 69W
Manufacturer/model:
XT660R METZELER/TOURANCE,
MICHELIN/SIRAC
XT660X PIRELLI/DRAGON,
METZELER/SPORTEC M1,
MICHELIN/RADIAL PILOT SPORTLoading: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
U5VKE1E0.book Page 2 Tuesday, July 18, 2006 1:00 PM

SPECIFICATIONS
8-3
8
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
XT660R 225.0 mm (8.86 in)
XT660X 200.0 mm (7.87 in)Rear suspension:Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
XT660R 200.0 mm (7.87 in)
XT660X 191.0 mm (7.52 in)Electrical system:Ignition system:
Transistorized coil ignition (digital)
Charging system:
AC magnetoBattery:Model:
GT9B-4Voltage, capacity:
12 V, 8.0 Ah
Headlight:Bulb type:
Halogen bulbBulb voltage, wattage × quantity:Headlight:
12 V, 55 W/60.0 W × 1
Tail/brake light:
12 V, 5.0 W/21.0 W × 1
Front turn signal light:
12 V, 10.0 W × 2
Rear turn signal light:
12 V, 10.0 W × 2
Auxiliary light:
12 V, 5.0 W × 1
Meter lighting:
EL
Neutral indicator light:
LED
High beam indicator light:
LED
Turn signal indicator light:
LED
Fuel level warning light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LED
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30.0 A
Headlight fuse:
20.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Parking lighting fuse:
10.0 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10.0 A
Backup fuse:
10.0 A
U5VKE1E0.book Page 3 Tuesday, July 18, 2006 1:00 PM

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
U5VKE1E0.book Page 1 Tuesday, July 18, 2006 1:00 PM