2004 YAMAHA XT660R wheel bolts

PRE-OPERATION CHECKS
4-3
4
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-17, 6-25
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-25
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-23, 6-24
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-17, 6-19
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-26
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-25
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-26
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-14 ITEM CHECKS PAGE

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 500 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
21*Electronic fuel injectionAdjust engine idling speed.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU23290
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAUM1730
Battery This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.CAUTION:
ECA10620
Never attempt to remove the battery
cell seals, as this would permanent-ly damage the battery.
To access the battery
1. Remove the seat. (See page
3-12.)
2. Remove the battery cover by re-
moving the bolts.

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