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Yamaha XT660R S Service Manual

Yamaha XT660R S
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3 - 23
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
7. Install:
spark plug
8. Connect:
spark plug cap
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
_
Place the motorcycle on a suitable stand.
Make sure the motorcycle is upright.
2. Start the engine, warm it up for 10 ~ 15 min-
utes, and then turn it off.
3. Check:
engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark Add the
recommended engine oil to the proper level.
NOTE:
_
Before checking the engine oil level, wait a
few minutes until the oil has settled.
Do not screw the dipstick 1 in when check-
ing the oil level.
CAUTION:
_
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and
do not use oils labeled ENERGY CON-
SERVING II d or higher.
Do not allow foreign materials to enter the
crankcase.
Recommended oil
Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temper-
atures.
API standard
SE, SF, SG or higher grade
T
R
.
.
13 Nm (1.3 m · kg, 9.4 ft · lb)
-20 -10 0
10
20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40
SAE 20W-40
SAE 20W-50
SAE 10W-40

Table of Contents

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Yamaha XT660R S Specifications

General IconGeneral
Displacement660 cc
Bore x Stroke100.0 mm x 84.0 mm
Compression Ratio10.0:1
Fuel SystemFuel Injection
Ignition SystemTCI
Starter SystemElectric
Transmission System5-speed
Final DriveChain
Front Suspension SystemTelescopic forks
Front Tyre90/90-21 M/C 54S
Rear Tyre130/80-17 M/C 65S
Overall Width865 mm
Overall Height1, 230 mm
Seat Height865 mm
Wheelbase1, 505 mm
Wet Weight181 kg
Fuel Tank Capacity15 litres
Oil Tank Capacity2.9 litres
Engine TypeLiquid-cooled, 4-stroke, single cylinder, SOHC
Maximum Power48hp (35kW) @ 6, 000rpm
FrameSteel diamond
Rear Suspension SystemSwingarm, (link suspension)
Front BrakeSingle 298mm disc, 2-piston caliper
Rear BrakeSingle Disc, 245 mm

Summary

General Information

Motorcycle Identification

Details on identifying the motorcycle, including VIN and model label.

Features

Overview of key features and outline of the motorcycle's systems.

Important Information

Crucial guidelines for maintenance, disassembly, and parts handling.

Special Tools

List of specialized tools required for tune-up and assembly.

Specifications

General Specifications

Key dimensions, weight, and model codes for the motorcycle.

Engine Specifications

Detailed technical data for the engine, including bore, stroke, and oil.

Chassis Specifications

Technical data related to the frame, wheels, tires, brakes, and suspension.

Electrical Specifications

Technical data for the electrical system components, including battery and ignition.

Engine Tightening Torque

Specific torque values for engine components during assembly.

Chassis Tightening Torques

Specific torque values for chassis components during assembly.

Lubrication Points and Lubricant Types

Identifies lubrication points and recommended lubricant types for engine and chassis.

Cable Routing

Instructions and diagrams for routing electrical and control cables.

Periodic Checks and Adjustments

Introduction

Overview of recommended checks and adjustments for reliable vehicle operation.

Periodic Maintenance and Lubrication Chart

Schedule of regular maintenance tasks based on mileage and time.

Cowling and Cover

Procedures for removing and installing fairings, seat, and covers.

Fuel Tank

Steps for removing, installing, and checking the fuel tank and pump.

Air Filter Case

Procedures for removing and installing the air filter and related components.

Engine

Checks and adjustments for engine components like valve clearance and idling speed.

Chassis

Front Wheel and Brake Disc

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

Rear Wheel, Brake Disc, and Rear Wheel Sprocket

Procedures for removing, checking, and installing the rear wheel, brake disc, and sprocket.

Front and Rear Brakes

Detailed procedures for brake pads, calipers, master cylinders, and fluid.

Front Fork

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

Handlebar

Procedures for removing, checking, and installing the handlebar and its components.

Steering Head

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

Rear Shock Absorber Assembly

Procedures for handling, removing, checking, and installing the rear shock absorber.

Swingarm and Drive Chain

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

Engine

Engine Removal

Steps for removing exhaust, leads, cables, hoses, ignition coil, and engine.

Cylinder Head

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

Rocker Arms and Camshaft

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

Valves and Valve Springs

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

Cylinder and Piston

Procedures for removing, checking, and installing the cylinder and piston.

Clutch

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

Starter Clutch and A.C. Magneto

Procedures for removing, checking, and installing the starter clutch and A.C. magneto.

Crankcase

Procedures for separating, checking, and assembling the crankcase.

Crankshaft

Procedures for removing, checking, and installing the crankshaft assembly.

Transmission

Procedures for removing, checking, and installing the transmission components.

Cooling System

Radiator

Procedures for removing, checking, and installing the radiator and cap.

Thermostat

Procedures for checking and installing the thermostat.

Water Pump

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

Fuel Injection System

Fuel Injection System

Overview of the fuel injection system, including wiring and ECU functions.

Wiring Diagram

Schematic showing electrical connections for the fuel injection system.

ECU Self-Diagnostic Function

Explanation of the ECU's self-diagnostic capabilities and fault codes.

Troubleshooting Chart

Guide to diagnosing and resolving engine trouble warnings and FI system issues.

Diagnostic Mode

Instructions for accessing and using the diagnostic mode on the meter.

Electrical System

Electrical Components

Illustration and list of major electrical components on the motorcycle.

Checking Switch Continuity

Procedure for testing switch continuity using a pocket tester.

Checking the Switches

Guide to checking switches for damage, connections, and continuity.

Checking the Bulbs and Bulb Sockets

Procedures for checking bulbs, sockets, and LEDs for damage or proper function.

Ignition System Circuit Diagram

Schematic illustrating the ignition system's wiring.

Troubleshooting

Guide to diagnosing and resolving ignition system failures.

Electric Starting System Circuit Diagram

Schematic showing the electric starting system's wiring.

Starter Motor

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

Charging System Circuit Diagram

Schematic illustrating the charging system's wiring.

Troubleshooting

Guide to diagnosing and resolving charging system failures.

Lighting System Circuit Diagram

Schematic showing the lighting system's wiring.

Troubleshooting

Guide to diagnosing and resolving lighting system failures.

Signaling System Circuit Diagram

Schematic showing the signaling system's wiring.

Troubleshooting

Guide to diagnosing and resolving signaling system failures.

Cooling System Circuit Diagram

Schematic showing the cooling system's wiring.

Troubleshooting

Guide to diagnosing and resolving cooling system failures.

Immobilizer System Circuit Diagram

Schematic showing the immobilizer system's wiring.

General Information

Overview of the motorcycle's immobilizer system features.

Key Code Registration

Procedures for registering or replacing keys for the immobilizer system.

Self-Diagnosis Malfunction Codes

List and explanation of malfunction codes displayed by the immobilizer system.

Troubleshooting

Guide to diagnosing and resolving immobilizer system failures.

Troubleshooting

Starting Failures

Common causes and checks for engine, fuel system, and electrical starting issues.

Incorrect Engine Idling Speed

Troubleshooting steps for abnormal engine idling speed related to engine, fuel, or electrical systems.

Poor Medium-and-High-Speed Performance

Troubleshooting for issues affecting engine and fuel system performance at higher speeds.

Faulty Gear Shifting

Diagnosing and resolving problems with gear shifting, including difficulty or jumping out of gear.

Faulty Clutch

Troubleshooting for clutch issues like slipping, dragging, or improper assembly.

Overheating

Diagnosing causes of engine, cooling system, fuel system, chassis, and electrical overheating.

Poor Braking Performance

Diagnosing causes of poor braking performance, including worn parts and fluid issues.

Faulty Front Fork Legs

Troubleshooting for front fork oil leaks or other malfunctions.

Unstable Handling

Diagnosing causes of unstable handling related to handlebar, steering, tires, wheels, or frame.

Faulty Lighting or Signaling System

Troubleshooting for issues with headlights, turn signals, brake lights, and horn.

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