2008 YAMAHA XT660X air filter

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 ................. 6-9
Engine oil and oil filter element .... 6-10
Coolant ......................................... 6-13
Replacing the air filter element and
cleaning the check hose ........... 6-16
Adjusting the engine idling
speed ........................................ 6-17
Checking the throttle cable free
play ........................................... 6-18
Tires ............................................. 6-18
Spoke wheels ............................... 6-21
Adjusting the clutch lever free
play ........................................... 6-21
Adjusting the rear brake light
switch ........................................ 6-22Checking the front and rear brake
pads .......................................... 6-22
Checking the brake fluid level ...... 6-23
Drive chain slack .......................... 6-24
Cleaning and lubricating the drive
chain ......................................... 6-26
Checking and lubricating the
cables ....................................... 6-27
Checking and lubricating the
throttle grip and cable ............... 6-27
Checking and lubricating the
brake and clutch levers ............ 6-27
Lubricating the brake pedal ......... 6-28
Checking and lubricating the
sidestand .................................. 6-28
Checking the front fork ................. 6-29
Checking the steering .................. 6-29
Checking the wheel bearings ....... 6-30
Battery ......................................... 6-30
Replacing the fuses ..................... 6-32
Replacing the headlight bulb ....... 6-33
Replacing a turn signal light bulb
or the tail/brake light bulb ......... 6-34
Replacing an auxiliary light bulb .. 6-35
Supporting the motorcycle ........... 6-35
Front wheel .................................. 6-36
Rear wheel ................................... 6-37
Troubleshooting ........................... 6-39
Troubleshooting charts ................ 6-40U5VKE1E0.book Page 1 Tuesday, July 18, 2006 1:00 PM

DESCRIPTION
2-2
2
EAU10420
Right view1. Owner’s tool kit (page 6-1)
2. Air filter element (page 6-16)
3. Shock absorber assembly spring preload adjusting ring (page 3-13)
4. Rear brake fluid reservoir (page 6-23)
5. Front brake fluid reservoir (page 6-23)
6. Engine oil filler cap (page 6-10)
7. Engine oil drain bolt (oil tank) (page 6-10)
8. Coolant reservoir (page 6-13)9. Engine oil filter element (page 6-10)
10.Coolant drain bolt (page 6-14)
11.Brake pedal (page 3-10)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√
4 Air filter elementReplace.√√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAUM1890
NOTE:

Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder, and change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
23 Engine oil filter elementReplace.√√√
24*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
25*Front and rear brake
switchesCheck operation.√√√√√ √
26Moving parts and ca-
blesLubricate.√√√√ √
27*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace the entire air induction system if necessary.√√√√ √
29*Mufflers and exhaust
pipesCheck the screw clamps for looseness.√√√√√ √
30*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040U5VKE1E0.book Page 4 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
62. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAUM1841
Engine oil and oil filter ele-
ment The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for 10–
15 minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:

The engine oil tank is located in-
side of the frame.


The engine oil should be between
the minimum and maximum levelmarks.
CAUTION:
ECA10010
Do not operate the vehicle until you
know that the engine oil level is suf-ficient.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
WARNING
EWA10360
Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oiltank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Install the engine oil drain attach-
ment, provided with the owner’s
tool kit, under the drain bolt of the
crankcase.3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap
and the drain bolt to drain the oil
from the crankcase.
5. Remove the drain bolt to drain the
oil from the oil tank.6. Remove the oil filter element drain
bolt to drain the oil from the oil filter
element.
NOTE:
Skip steps 7–9 if the oil filter element isnot being replaced.
7. Remove the oil filter element cover
by removing the bolts.
1. Engine oil drain bolt (crankcase)
2. Engine oil drain attachment
1. Engine oil drain bolt (oil tank)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
68. Remove and replace the oil filter
element and O-rings.9. Install the oil filter element cover by
installing the bolts and the oil filter
element drain bolt, then tightening
them to the specified torques.
NOTE:Make sure that the O-rings are properlyseated.
10. Install the oil drain bolts, and then
tighten them to the specified
torques.
11. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
ECAM1060
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt) of
the recommended engine oil. Then,
start the engine, race it 5 or 6 times,
turn it off, and then add the remain-der of the engine oil.CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
1. Oil filter element cover bolt
2. Oil filter element drain bolt
1. Oil filter element
2. O-ring
Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt (crankcase):
30 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank):
18 Nm (1.8 m·kgf, 13 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
616. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
17. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
18. Install the cowling, the panel and
the seat.
EAUM1833
Replacing the air filter element
and cleaning the check hose The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if neces-
sary.
To replace the air filter element
1. Remove the seat. (See page
3-12.)
2. Remove panel B. (See page 6-5.)
3. Remove the air filter case cover by
removing the screws.4. Pull the air filter element out.
5. Insert a new air filter element into
the air filter case as shown.
1. Air filter case cover
2. Screw
1. Air filter element
U5VKE1E0.book Page 16 Tuesday, July 18, 2006 1:00 PM