2004 YAMAHA XT660R Owners Manual

MOTORCYCLE CARE AND STORAGE
7-4
7 4. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlets with plas-
tic bags to prevent moisture from
entering them.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-28.
NOTE:Make any necessary repairs beforestoring the motorcycle.

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
XT660R 2240 mm (88.2 in)
XT660X 2150 mm (84.6 in)
Overall width:
XT660R 845 mm (33.3 in)
XT660X 865 mm (34.1 in)
Overall height:
XT660R 1230 mm (48.4 in)
XT660X 1210 mm (47.6 in)
Seat height:
XT660R 865 mm (34.1 in)
XT660X 870 mm (34.3 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 (40.27 cu.in)
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 or SAE10W40 or SAE15W40
or 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)Electronic fuel injection:Manufacturer:
DENSO
Model:
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

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
Manufacturer/model:
XT660R METZELER/TOURANCE FRONT
XT660X PIRELLI/DRAGON
Manufacturer/model:
XT660R MICHELIN/SIRAC
Rear tire:Type:
With tube
Size:
XT660R 130/80-17M/C 65S, 130/80-
17M/C 65T
XT660X 160/60R17 M/C 69H
Manufacturer/model:
XT660R METZELER/TOURANCE
XT660X PIRELLI/DRAGON
Manufacturer/model:
XT660R MICHELIN/SIRAC ALoading: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
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4

SPECIFICATIONS
8-3
8
Front 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:
A.C. magnetoBattery:Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 AhHeadlight:Bulb type:
Halogen bulbBulb voltage, wattage x quantity:Headlight:
12 V, 55 W/60.0 W × 1
Tail/brake light:
12 V, 5.0/21.0 W × 1Front 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 indicator 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 ARadiator fan fuse:
7.5 A
Electronic fuel injection fuse:
10.0 A
Backup fuse:
10.0 A

CONSUMER INFORMATION
9-1
9
EAU26351
Identification numbers Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
EAU26381
Key identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
EAU26410
Vehicle identification number
The vehicle identification number is
stamped into the frame.NOTE:
The vehicle identification number is
used to identify your vehicle and may
be used to register it with the licensingauthority in your area.
1. Key identification number
2. Code re-registering key (red bow)
3. Standard keys (black bow)
1. Vehicle identification number

CONSUMER INFORMATION
9-2
9
EAU26540
Model label
The model label is affixed to the frame
under the seat. (See page 3-12.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.1. Model label

INDEX
AAir filter element and check hose,
replacing and cleaning ....................... 6-15
Anti-theft alarm (optional) ....................... 3-7
Auxiliary light bulb, replacing ................ 6-33BBattery .................................................. 6-28
Brake and clutch levers, checking
and lubricating .................................... 6-25
Brake fluid level, checking .................... 6-22
Brake lever ............................................. 3-9
Brake pedal .......................................... 3-10
Brake pedal, lubricating ........................ 6-26CCables, checking and lubricating .......... 6-25
Care ........................................................ 7-1
Catalytic converter ................................ 3-12
Clutch lever............................................. 3-9
Clutch lever free play, adjusting ........... 6-20
Coolant ................................................. 6-12
Coolant temperature warning light.......... 3-4
Cowlings and panels, removing and
installing ............................................... 6-5DDimmer switch ........................................ 3-8
Drive chain, lubricating ......................... 6-24
Drive chain slack .................................. 6-23EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-16
Engine oil and oil filter element............... 6-9
Engine stop switch.................................. 3-8
Engine trouble warning light ................... 3-4
FFront and rear brake pads, checking .... 6-21
Front fork, checking...............................6-27
Fuel ....................................................... 3-11
Fuel consumption, tips for reducing ........ 5-3
Fuel level warning light............................ 3-4
Fuel tank cap......................................... 3-10
Fuses, replacing .................................... 6-30HHandlebar switches ................................. 3-7
Hazard switch.......................................... 3-8
Headlight bulb, replacing....................... 6-31
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 ......... 6-21SSafety 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 ..... 6-26
Spark plug, checking .............................. 6-7
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ............................................. 3-8
Steering, checking ................................ 6-27
Storage ................................................... 7-3
Storage compartment ........................... 3-13
Supporting the motorcycle .................... 6-33TThrottle cable free play, adjusting ......... 6-17
Throttle grip and cable, checking
and lubricating .................................... 6-25
Tires ...................................................... 6-17
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-37
Troubleshooting charts ......................... 6-38
Turn signal indicator light ........................ 3-3
Turn signal light bulb or tail/brake
light bulb, replacing............................. 6-32
Turn signal switch ................................... 3-8VVehicle identification number .................. 9-1

INDEXWWheel bearings, checking ..................... 6-28
Wheel (front) ......................................... 6-34
Wheel (rear) .......................................... 6-35
Wheels .................................................. 6-19