2004 YAMAHA XT660R ECU

SAFETY INFORMATION
1-3
1


Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamahaaccessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas


GASOLINE IS HIGHLY FLAMMA-
BLE:
Always turn the engine off when
refueling.

INSTRUMENT AND CONTROL FUNCTIONS
3-1
3
EAU10972
Immobilizer system This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing.

a code re-registering key (with a
red bow)


two standard keys (with a black
bow) that can be re-registered with
new codes


a transponder (which is installed in
the code re-registering key)


an immobilizer unit


an ECU


an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-reg-
istered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
CAUTION:
ECA11820


DO NOT LOSE THE CODE RE-
REGISTERING KEY! CONTACT
YOUR DEALER IMMEDIATELY
IF IT IS LOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard
keys can still be used to start
the vehicle, however if code re-
registering is required (i.e., if a
new standard key is made or all
keys are lost) the entire immobi-
lizer system must be replaced.
Therefore, it is highly recom-mended to use either standard
key and keep the code re-regis-
tering key in a safe place.


Do not submerse any key in wa-
ter.


Do not expose any key to exces-
sively high temperatures.


Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).


Do not place heavy items on any
key.


Do not grind any key or alter its
shape.


Do not disassemble the plastic
part of any key.


Do not put two keys of any im-
mobilizer system on the same
key ring.


Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle’s code re-registering key.


Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-ference.
1. Code re-registering key (red bow)
2. Standard keys (black bow)

INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
EAU14421
Storage compartment This storage compartment is designed
to hold a genuine Yamaha U-LOCK.
(Other locks may not fit.) When placing
a U-LOCK in the storage compartment,
securely fasten it with the straps. When
the U-LOCK is not in the storage com-
partment, be sure to secure the straps
to prevent losing them.
WARNING
EWA10961


Do not exceed the load limit of 3
kg (7 lb) for the storage com-
partment.


Do not exceed the maximum
load of 186 kg (410 lb) for the ve-hicle.
EAU14830
Adjusting the shock absorber
assembly This shock absorber assembly is
equipped with a spring preload adjust-
ing ring.CAUTION:
ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum orminimum settings.
Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To de-
1. U-LOCK bar (optional)
2. Yamaha U-LOCK (optional)
3. Strap
1. Spring preload adjusting ring
2. Special wrench
3. Position indicator

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
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.
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.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6 4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAUM1750
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove cowling A together with
the headlight unit. (See page 6-5.)
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
4. Place a new bulb into position, and
then secure it with the bulb holder.CAUTION:
ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
1. Headlight bulb cover
2. Headlight coupler
1. Headlight bulb holder
2. Headlight bulb

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
EAU24360
Front wheel
EAUM1761
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the front wheel axle pinch
bolts, then the wheel axle and the
brake caliper bolts.
XT660RXT660X
2. Lift the front wheel off the ground
according to the procedure on
page 6-33.
3. Remove the brake caliper by re-
moving the bolts.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
4. Pull the wheel axle out, and then
remove the wheel.
EAUM1811
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
1. Wheel axle
2. Front wheel axle pinch bolt A
3. Front wheel axle pinch bolt B
1. Wheel axle
2. Front wheel axle pinch bolt A
3. Front wheel axle pinch bolt B
1. Bolt
2. Brake caliper

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6 4. Install the brake caliper by install-
ing the bolts.
NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brakedisc.
5. Tighten the wheel axle to the spec-
ified torque.
6. Tighten the wheel axle pinch bolt A
and pinch bolt B to the specified
torques.
7. Retighten the wheel axle pinch bolt
A to the specified torque.
8. Tighten the brake caliper bolts to
the specified torques.
9. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAUM1771
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Remove the drive chain guard by
removing the bolts.
XT660RXT660X
2. Loosen the axle nut.
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
1. Bolt
2. Drive chain guard
1. Bolt
2. Drive chain guard
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
4. Brake caliper bracket
5. Brake caliper