2008 YAMAHA XT660X engine oil

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
2-1
2
EAU10410
Left view1. Windshield
2. Idle adjusting screw (page 6-17)
3. Main fuse (page 6-32)
4. Battery (page 6-30)
5. Fuse box 1 (page 6-32)
6. Fuse box 2 (page 6-32)
7. Storage compartment (page 3-13)
8. Grab bar9. Seat lock (page 3-12 )
10.Shift pedal (page 3-9)
11.Engine oil drain bolt (crankcase) (page 6-10)U5VKE1E0.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

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU16810
Tips for reducing fuel con-
sumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17030
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
CAUTION:
ECA11440
After 1000 km (600 mi) of operation,
the engine oil must be changed, andthe oil filter element cleaned.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealercheck the vehicle.
U5VKE1E0.book Page 3 Tuesday, July 18, 2006 1:00 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17520
Owner’s tool kit The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-12.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
2. Engine oil drain attachment
U5VKE1E0.book Page 1 Tuesday, July 18, 2006 1:00 PM

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, alignment and condition.
Adjust and lubricate chain with a special O-ring chain lu-
bricant thoroughly.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*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
U5VKE1E0.book Page 3 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