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Yamaha XT660X 2004 User Manual

Yamaha XT660X 2004
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2004
XT660R(S)
XT660X(S)
5VK1-AE1
SERVICE MANUAL

Table of Contents

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Yamaha XT660X 2004 Specifications

General IconGeneral
Displacement660 cc
Compression Ratio10.0:1
Fuel SystemElectronic Fuel Injection
IgnitionTCI
Starting SystemElectric
Transmission5-speed
Final DriveChain
Rear BrakeSingle disc, 245 mm
Overall Width865 mm
Wet Weight186 kg
Fuel Capacity15 liters
Engine Type4-stroke, single cylinder, 4 valves
Bore x Stroke100 mm x 84 mm
Max Power35.3 kW (48 PS) @ 6, 000 rpm
Max Torque58 Nm @ 5, 250 rpm
Front SuspensionTelescopic fork
Rear SuspensionSwingarm
Front BrakeSingle disc
Front Tire120/70-17
Rear Tire160/60-17

Summary

General Information

Motorcycle Identification

Details on identifying the motorcycle model and VIN.

Features

Overview of key features and the FI system.

Important Manual Information

Guidelines for using the manual and important precautions.

Special Tools

List of specialized tools required for maintenance.

Specifications

General Specifications

Key dimensions, weight, and load capacity.

Engine Specifications

Detailed engine performance and component specifications.

Chassis Specifications

Frame, wheel, tire, and suspension specifications.

Electrical Specifications

Details on the electrical system components and performance.

General Tightening Torque Specifications

Specifications for tightening standard fasteners.

Periodic Checks and Adjustments

Periodic Maintenance and Lubrication Chart

Schedule for routine maintenance tasks based on mileage and time.

Cowling and Cover

Procedures for removing and installing body panels.

Fuel Tank

Steps for removing and installing the fuel tank and pump.

Air Filter Case

Procedures for accessing and maintaining the air filter.

Engine

Checks and adjustments for engine components and systems.

Chassis

Checks and adjustments for chassis components like brakes and suspension.

Electrical System

Checks and charging procedures for the battery.

Chassis

Front Wheel and Brake Disc

Procedures for removing, checking, and installing the front wheel and brake.

Rear Wheel, Brake Disc, and Rear Wheel Sprocket

Steps for removing, checking, and installing the rear wheel and drive components.

Front and Rear Brakes

Procedures for checking and replacing brake pads and servicing calipers.

Front Fork

Procedures for removing, disassembling, checking, and installing front fork legs.

Handlebar

Steps for removing, checking, and installing the handlebar.

Steering Head

Procedures for removing, checking, and installing the steering head components.

Rear Shock Absorber Assembly

Handling, removal, checking, and installation of the rear shock absorber.

Swingarm and Drive Chain

Procedures for removing, checking, and installing the swingarm and drive chain.

Engine

Engine Removal

Procedures for removing the exhaust, leads, cables, and the engine itself.

Cylinder Head

Procedures for removing, checking, and installing the cylinder head assembly.

Rocker Arms and Camshaft

Steps for removing, checking, and installing rocker arms and camshaft.

Valves and Valve Springs

Procedures for removing, checking, and installing valves and springs.

Cylinder and Piston

Steps for removing, checking, and installing the cylinder and piston assembly.

Clutch

Procedures for removing, checking, and installing clutch components.

Oil Pump

Procedures for checking, assembling, and installing the oil pump.

Balancer Driven Gear

Procedures for removing, checking, and installing balancer gears.

Shift Shaft

Procedures for checking and installing the shift shaft and stopper lever.

Starter Clutch and A.C. Magneto

Procedures for checking and installing starter clutch and A.C. magneto.

Crankcase

Procedures for separating, checking, and assembling the crankcase.

Crankshaft

Procedures for removing, checking, and installing the crankshaft.

Transmission

Procedures for removing, checking, and installing transmission components.

Cooling System

Radiator

Procedures for removing, checking, and installing the radiator.

Thermostat

Procedures for checking and installing the thermostat.

Water Pump

Procedures for removing, checking, assembling, and installing the water pump.

Fuel Injection System

Fuel Injection System

Overview of the FI system, wiring diagram, and diagnostic functions.

Throttle Body Assembly

Procedures for checking and installing the throttle body assembly and related components.

Air Induction System

Overview of the air induction system and its components.

Electrical System

Electrical Components

Identification and location of major electrical components.

Checking Switch Continuity

Procedure for testing switch continuity using a pocket tester.

Checking the Switches

General checks for switch damage, wear, and connections.

Checking the Bulbs and Bulb Sockets

Procedures for checking bulb and socket condition and continuity.

Ignition System

Circuit diagram and troubleshooting for the ignition system.

Electric Starting System

Circuit diagram and troubleshooting for the electric starting system.

Starter Motor

Procedures for removing, disassembling, checking, and assembling the starter motor.

Charging System

Circuit diagram and troubleshooting for the charging system.

Lighting System

Circuit diagram and troubleshooting for the lighting system.

Signaling System

Circuit diagram and troubleshooting for turn signals, horn, and lights.

Cooling System

Circuit diagram and troubleshooting for the cooling fan.

Immobilizer System

General information, key code registration, and troubleshooting for the immobilizer.

Self-Diagnosis

Information on self-diagnosis and troubleshooting for the fuel level warning light.

Troubleshooting

Starting Failures

Common causes for engine starting failures.

Incorrect Engine Idling Speed

Potential causes for improper engine idling speed.

Poor Medium-and-High-Speed Performance

Factors affecting engine performance at higher speeds.

Faulty Gear Shifting

Issues related to difficult gear shifting and pedal movement.

Faulty Clutch

Common problems like clutch slipping or dragging.

Overheating

Causes for engine, cooling, fuel system, and electrical overheating.

Overcooling

Causes for engine overcooling.

Poor Braking Performance

Common issues affecting brake performance.

Faulty Front Fork Legs

Problems related to oil leaks or malfunctions in the front fork.

Unstable Handling

Factors contributing to unstable motorcycle handling.

Faulty Lighting or Signaling System

Troubleshooting for lighting and signaling system failures.

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