2008 YAMAHA XT660X lock

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
NOTE:Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-sition for proper wheel alignment.CAUTION:
ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within thespecified limits.3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
EAU34311
To adjust the drive chain slack
(XT660X)
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction (b), and then
push the rear wheel forward.NOTE:Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-tion for proper wheel alignment.
CAUTION:
ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within thespecified limits.
3. Tighten the locknuts, then the axle
nut to their specified torques.
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
4. Alignment marks
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
4
3
12(a)
(b)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU23022
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.CAUTION:
ECA10581
The drive chain must be lubricated
after washing the motorcycle andriding in the rain.
1. Clean the drive chain with kero-
sene and a small soft brush.CAUTION:
ECA11120
To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers orinappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
CAUTION:
ECA11110
Do not use engine oil or any other lu-
bricants for the drive chain, as they
may contain substances that coulddamage the O-rings.
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
U5VKE1E0.book Page 26 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
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. Fuel injection system fuse
6. Radiator fan fuse
7. Backup fuse (for odometer, clock and immo-
bilizer 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
Fuel injection system fuse:
10.0 A
Backup fuse:
10.0 A
Fuse box 2:
Parking lighting fuse:
10.0 A
U5VKE1E0.book Page 32 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
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
EAUM1773
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.
XT660R
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6XT660X
3. Lift the rear wheel off the ground
according to the procedure on
page 6-35.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing nuts (or bolts according to the
model) fully in direction (a).
6. Remove the wheel axle by remov-
ing the axle nut.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain cannot be disassem-bled.
8. Pull the wheel backward and move
the brake caliper away from the
wheel.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.
EAUM2140
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Install the wheel, the washer(s)
and the brake caliper bracket by
inserting the wheel axle from the
left-hand side.NOTE:

XT660R: Install the washer with
the “N” mark on the right-hand side
and the washer with the “O” mark
on the left-hand side. Be sure to in-
stall both washers with their marks
facing outward.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper bracket
5. Brake caliper
3
1245(a)
1. Brake caliper
2. Brake disc
U5VKE1E0.book Page 38 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6


XT660X: Install the washer on the
right-hand side.


Make sure that the retainer on the
swingarm is inserted into the slot in
the brake caliper bracket.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.
3. Lower the rear wheel so that it is
on the ground.
4. Adjust the drive chain slack. (See
page 6-24.)
5. Tighten the axle nut to the speci-
fied torque.6. Install the drive chain guard by in-
stalling the bolts.
EAU25870
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Retainer
2. Slot
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
U5VKE1E0.book Page 39 Tuesday, July 18, 2006 1:00 PM