2008 YAMAHA XT660X brake fluid

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)
U5VKE1E0.book Page 2 Tuesday, July 18, 2006 1:00 PM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-11
Engine oilCheck oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-21
U5VKE1E0.book Page 2 Tuesday, July 18, 2006 1:00 PM

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
U5VKE1E0.book Page 2 Tuesday, July 18, 2006 1:00 PM

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
6-23
6 indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU22580
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
U5VKE1E0.book Page 23 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22782
To check the drive chain slack
1. Place the motorcycle on the side-
stand.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
4. If the drive chain slack is incorrect,
adjust it as follows.
NOTE:When checking the drive chain slack,
the chain tensioner should not betouching the drive chain.
EAU22932
To adjust the drive chain slack
(XT660R)
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
1. Drive chain slack
Drive chain slack:
40.0–55.0 mm (1.57–2.17 in)
U5VKE1E0.book Page 24 Tuesday, July 18, 2006 1:00 PM

SPECIFICATIONS
8-3
8
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4Front 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:
AC magnetoBattery:Model:
GT9B-4Voltage, capacity:
12 V, 8.0 Ah
Headlight:Bulb type:
Halogen bulbBulb voltage, wattage × quantity:Headlight:
12 V, 55 W/60.0 W × 1
Tail/brake light:
12 V, 5.0 W/21.0 W × 1
Front 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 warning 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 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10.0 A
Backup fuse:
10.0 A
U5VKE1E0.book Page 3 Tuesday, July 18, 2006 1:00 PM