2004 YAMAHA XT660R headlight bulb

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Multi-function display ......................3-5
Anti-theft alarm (optional) ...............3-7
Handlebar switches ........................3-7
Clutch lever .....................................3-9
Shift pedal .......................................3-9
Brake lever .....................................3-9
Brake pedal ..................................3-10
Fuel tank cap ................................3-10
Fuel ...............................................3-11
Catalytic converter ........................3-12
Seat ..............................................3-12
Storage compartment ...................3-13
Adjusting the shock absorber
assembly ...................................3-13
Sidestand ......................................3-14
Ignition circuit cut-off system ........3-15
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing cowlings
and panels .................................. 6-5
Checking the spark plug ................. 6-7
Engine oil and oil filter element ...... 6-9
Coolant ......................................... 6-12
Replacing the air filter element and
cleaning the check hose ........... 6-15
Adjusting the engine idling
speed ........................................ 6-16
Adjusting the throttle cable free
play ........................................... 6-17
Tires .............................................. 6-17
Spoke wheels ............................... 6-19
Adjusting the clutch lever free
play ........................................... 6-20
Adjusting the rear brake light
switch ........................................ 6-21Checking the front and rear
brake pads ................................ 6-21
Checking the brake fluid level ...... 6-22
Drive chain slack .......................... 6-23
Lubricating the drive chain ........... 6-24
Checking and lubricating the
cables ....................................... 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and clutch levers ............ 6-25
Lubricating the brake pedal ......... 6-26
Checking and lubricating the
sidestand .................................. 6-26
Checking the front fork ................. 6-27
Checking the steering .................. 6-27
Checking the wheel bearings ....... 6-28
Battery ......................................... 6-28
Replacing the fuses ..................... 6-30
Replacing the headlight bulb ....... 6-31
Replacing a turn signal light bulb
or the tail/brake light bulb ......... 6-32
Replacing an auxiliary light
bulb ........................................... 6-33
Supporting the motorcycle ........... 6-33
Front wheel .................................. 6-34
Rear wheel ................................... 6-35
Troubleshooting ........................... 6-37
Troubleshooting charts ................ 6-38

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
6-32
6fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
5. Install the bulb cover, and then
connect the coupler.
6. Install the cowling together with
the headlight unit.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24281
Replacing a turn signal light
bulb or the tail/brake light bulb 1. Remove the lens by removing the
screws.2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
CAUTION:
ECA10680
Do not overtighten the screws, oth-erwise the lens may break.
1. Do not touch the glass part of the bulb.
1. Screw
1. Screw

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAUM1820
Replacing an auxiliary light
bulb If the auxiliary light bulb burns out, re-
place it as follows.
1. Remove cowling A together with
the headlight unit. (See page 6-5.)
2. Remove the auxiliary light socket
(together with the bulb) by pulling it
out.
3. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the auxiliary light socket (to-
gether with the bulb) by pushing it
in.
6. Install the cowling together with
the headlight unit.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placinga jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. Auxiliary light bulb socket

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

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