YAMAHA XT660X 2008 Workshop Manual
Manufacturer: YAMAHA, Model Year: 2008, Model line: XT660X, Model: YAMAHA XT660X 2008Pages: 92, PDF Size: 5.05 MB
Page 51 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6 addition, 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.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUM1722
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove cowl-
ing B (See page 6-5.), and then
open the reservoir cap.
4. Add coolant to the maximum level
mark, and then close the reservoir
cap.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
U5VKE1E0.book Page 13 Tuesday, July 18, 2006 1:00 PM
Page 52 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
CAUTION:
ECA10471
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 cooling 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.WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
5. Install the cowling.
NOTE:
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
If the engine overheats, see page6-40 for further instructions.
EAUM1802
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.
1. Radiator cap
2. Radiator cap retaining screw
3. Radiator cap retainer
4. Coolant reservoir cap
U5VKE1E0.book Page 14 Tuesday, July 18, 2006 1:00 PM
Page 53 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6 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.11. 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 the
recommended coolant into the ra-
diator and reservoir.
CAUTION:
ECA10471
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 cooling 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.
1. Bolt
1. Coolant drain bolt
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)
U5VKE1E0.book Page 15 Tuesday, July 18, 2006 1:00 PM
Page 54 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
616. 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.
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.
1. Air filter case cover
2. Screw
1. Air filter element
U5VKE1E0.book Page 16 Tuesday, July 18, 2006 1:00 PM
Page 55 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
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.2. 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).
1. Air filter check hose
U5VKE1E0.book Page 17 Tuesday, July 18, 2006 1:00 PM
Page 56 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
NOTE:
If the specified idling speed cannot be
obtained as described above, have aYamaha dealer make the adjustment.
EAU21381
Checking 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
Tires To 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. Idle adjusting screwEngine idling speed:
1400–1500 r/min
1. Throttle cable free play
U5VKE1E0.book Page 18 Tuesday, July 18, 2006 1:00 PM
Page 57 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
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.
Tire air pressure (measured on cold
tires):
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)
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)
Maximum load*:
186 kg (410 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
U5VKE1E0.book Page 19 Tuesday, July 18, 2006 1:00 PM
Page 58 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
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.
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 a
Yamaha 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.
Front tire:
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 58W
Manufacturer/model:
XT660R METZELER/TOURANCE
FRONT,
MICHELIN/SIRAC
XT660X PIRELLI/DRAGON,
METZELER/SPORTEC M1,
MICHELIN/RADIAL PILOT
SPORT
Rear tire:
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/TOU-
RANCE,
MICHELIN/SIRAC
XT660X PIRELLI/DRAGON,
METZELER/SPORTEC M1,
MICHELIN/RADIAL PILOT
SPORT
U5VKE1E0.book Page 20 Tuesday, July 18, 2006 1:00 PM
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)
U5VKE1E0.book Page 21 Tuesday, July 18, 2006 1:00 PM
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
U5VKE1E0.book Page 22 Tuesday, July 18, 2006 1:00 PM