2004 YAMAHA XT660R recommended

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU23100
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.
EAU23110
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU23180
Lubricating the brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU23200
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAUM1740
Replacing the fuses The main fuse is located behind panel
A. (See page 6-5.)
Fuse box 1 and fuse box 2 are located
under the seat. (See page 3-12.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
1. Main fuse
2. Spare main fuse
1. Fuse box 1
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Electronic fuel injection fuse
6. Radiator fan fuse
7. Backup fuse (for odometer, clock and
immobilizer system)
8. Parking lighting fuse
9. Fuse box 2
10.Spare fuse
Specified fuses:
Main fuse:
30.0 A
Fuse box 1:
Headlight fuse:
20.0 A
Signaling system fuse:
10.0 A
Radiator fan fuse:
7.5 A
Ignition fuse:
10.0 A
Electronic fuel injection fuse:
10.0 A
Backup fuse:
10.0 A
Fuse box 2:
Parking lighting fuse:
10.0 A

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6 Engine overheating
WARNING
EWA10400


Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.


After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissingsound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolantas soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.

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