Yamaha XT660R XT660X 2004 Service Repair Manual

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The Yamaha XT660R XT660X 2004 Service Repair Manual is a comprehensive guide with 462 pages covering various aspects of motorcycle repair and maintenance.

  • Chapter 1: General Information
    • Motorcycle identification
    • Vehicle identification number model label
    • Features outline FI system
    • Preparation for removal and disassembly
    • Replacement parts
    • Gaskets, oil seals, and O-rings
    • Lock washers/plates and cotter pins
    • Bearings and oil seals circlips
    • Checking the connections
    • Special tools
  • Chapter 2: Specifications
    • General, engine, chassis, and electrical specifications
    • Conversion table
    • General tightening torque specifications
    • Engine and chassis tightening torques
    • Lubrication points and lubricant types for engine and chassis
    • Cooling system diagrams
    • Lubrication chart and diagrams
    • Cable routing
  • Chapter 3: Periodic Checks and Adjustments
    • Periodic maintenance and lubrication chart
    • Various checks and adjustments for cowling, cover, fuel tank, air filter case, rear mud guard, rear fender, engine, and chassis
    • Brake, electrical system, and more
  • Chapter 4: Chassis
    • Front and rear wheel, brake disc, wheel sprocket, brakes, and calipers
  • Chapter 5: Engine
    • Engine removal, exhaust pipes, mufflers, cylinder head, valves, piston, clutch, oil pump, balancer driven gear, shift shaft, starter clutch, and AC magneto
  • Chapter 6: Cooling System
    • Radiator, thermostat, and water pump disassembly, checking, assembling, and installing
  • Chapter 7: Fuel Injection System
    • Wiring diagram, ECU self-diagnostic function, troubleshooting, throttle body assembly, fuel pump, throttle position sensor, air induction system, and more
  • Chapter 8: Electrical System
    • Checking electrical components, switches, bulbs, ignition system, electric starting system, charging system, lighting system, signaling system, and cooling system
  • Chapter 9: Troubleshooting
    • Addresses starting failures, incorrect engine idling speed, poor medium-and-high-speed performance, faulty gear shifting, clutch issues, overheating, overcooling, poor braking performance, and unstable handling

This manual is an invaluable resource for both professional mechanics and DIY enthusiasts, providing detailed instructions and diagrams for motorcycle repair and maintenance.

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