![Yamaha XT660 (2004) [462/462] Wiring diagram](/img/pdf.png)
Yamaha XT660 (2004) [462/462] Wiring diagram
![Yamaha XT660 (2004) [462/462] Wiring diagram](/views2/1121384/page462/bg1ce.png)
XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM
ON
OFF
P
-- -
-
(BLACK)
(BLACK)
(DARK BLUE)
(GRAY)
-
R/W
RR
L/W
B
B
SUB-WIRE HARNESS
MAIN HARNESS
A
G
Ch Lg
YB
Dg
YB
L/R
Ch
G
L/R
G
BY
Y
Br
B
L/R
B
B
(
BLUE
)
(
DARK GREEN
)
(
BLUE
)
B
L/G
B
B
B/Y
L/Y
B
B
L/R
B
(
BLACK
)
(
BLACK
)
Y
Br
B
B
B
Y
L/R
Y
BL
R/BL/BR/L
Br
L/W
L/WL/RR/WL/GL/YSbB/YLg
L/W
B/Y
Y/L
L/B
Y/G
G/R
Br/W
W
P/W
Gy
Y
B/W
B/LL/R
L
G/Y
Br/R
Y/B
R
R/L
R/BO
B
G
Ch
Y
L/W
Br/W
PLg
R/L
Br
R/Y
Br
Br/W
G
L/B
P
Y
Dg
Ch
BB
R
(BLACK)
(BLACK)
BB
L
WW
W
WW
W
G/WL/YGy G/W
L/B
R
B
R/B
R/W
L/W
R/B
B
B
B
B
B
BB2
BB3
BB1
BB4
B
G/W
BB
B1
B1
B2
B
R/L
LY
(BLACK)
B/L
B/L
P/W
(BLACK)
L
L
Y/G
B/L
Y
R/G
Ch
R/W
G/L
Dg
Y/L
G/W
Lg
B/W
Ch R/G
Y
G
G/L
R/W
R/W
Lg Y/L
R/G
B2 B
Y/LG/L
R/W
BBBR/G
G/W
Y/L
B/W
Lg
B/L
LW
P
B/W
O/R
Br
L
R/W
G/Y
R/L
L/W
R/YY/B
Br/W
Br
WWW
BR
Br/R
Br/R
R
Br/L
R
Br/L
Br/RR/W
R/LR/B
Br/W
B/L
G/RB/L
5
2
1
3
4
z
0
A
B
v
w
x
y
q
a
_
]
\
[
Z
X
L
KF
G
6
7
8
9
H
I
ED
C
J
M
N
O
P
Q
T
U
V
R
S
W
Y
k
s
e
d
fg h i
b
c
j
r
t
u
{
l
mn op
È
Gy
L
R
Br/L
Br/R
G/W
R R
R R
R
B
B
B
B
B
R
R/B L/B Br
R B Y
L/GL/YSbL/R
R/L
B/Y
L/B
R/W
Br
R/B
L/W
L/W
B
BB
R/L G/W
L/G
B/W B
P
L/R
L/R
L/R
B
Br
Y
Br
R/W
L
L
B
G/Y
W
R/G
R
R
R
Br
R/G
Br
Br/L
Br/L
Br/L
Br/R
R
Br
R/L
B/L
Y/G
L
B/L
P/W
L
B/L
B/L
G/R
B/L
Br/W
R/WBr/R
R/L
R/B
G/R
L
W
B/L
Br/W
Br/R
R/B
R
Gy
L/W
R/L
L/R
B/Y
L/B
Y/L
Y/B
G/Y
OO
R/B
W
L
B/L
Y
Y/G
P/W
Y
L
Lg
Y
Ch
G
G/L
G/W
R/G
R/W
B/W
Y/L
R/W
L/W
Lg
B
P
Br
G/L
R/W
BB
Y/L
B
BB
B1
BB3
BB4
BB2
Y Lg Ch G
B/Y
Br R/L L/W Br/W L/Y
L/R
B
Y
R/L
R/Y
Br
Br/W
L/W
Y/B
BB1
W
W
W
W
W
R
B
Sb
A
Y
A
G
Y
B
B B B B
G
A
Ch
A
Y
B
A
B
Lg Ch G
Dg
ChCh Dg G
A
Содержание
- Important manual information 4
- Notice 4
- How to use this manual 5
- Chk adj 6
- Gen info 6
- Symbols 6
- Trbl shtg 6
- Chassis 7
- Cooling system 7
- Electrical system 7
- Engine 7
- Fuel injection system 7
- General information 7
- Periodic checks and adjustments 7
- Specifications 7
- Table of contents 7
- Troubleshooting 7
- Chapter 1 general information 10
- Gen info 10
- General information 10
- Gen info 12
- General information 12
- Motorcycle identification 12
- 2 3 4 5 6 7 8 9 0 a 13
- B c d e f g h i j 13
- Features 13
- Gen info 13
- Outline the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti mum air fuel ratio in accordance with the engine operating conditions and the atmospheric tempera ture in a conventional carburetor system the air fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber despite the same volume of intake air the fuel volume requirement varies with the engine operating conditions such as acceleration deceleration or operation under a heavy load carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine as the requirements for engines to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a m 13
- 46 psi higher than the intake manifold pressure accordingly when the energizing signal from the ecu energizes the injector the fuel passage opens causing the fuel to be injected into the intake manifold only during the time the passage remains open therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied conversely the shorter the length of time the injector is energized injection duration the lesser the volume of fuel that is supplied the injection duration and the injection timing are controlled by the ecu signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor and coolant temperature sensor enable the ecu to determine the injection dura tion the injection timing is determined through the signal from the crankshaft position sensor as a result the volume of fuel that is required by the engine can be supplied at all times in a 14
- Features 14
- Fi system the fuel pump delivers fuel to the injector via the fuel filter the pressure regulator maintains the fuel pressure that is applied to the injector at 324 kpa 3 4 kg c 14
- Gen info 14
- Illustration is for reference only 14
- Gen info 15
- Important information 15
- Gen info 16
- Important information 16
- Checking the connections 17
- Gen info 17
- Gen info 18
- Special tools 18
- The following special tools are necessary for complete and accurate tune up and assembly use only the appropriate special tools as this will help prevent damage caused by the use of inappropri ate tools or improvised techniques special tools part numbers or both may differ depending on the country when placing an order refer to the list provided below to avoid any mistakes 18
- Tool no tool name function illustration 18
- Gen info 19
- Special tools 19
- Tool no tool name function illustration 19
- Gen info 20
- Special tools 20
- Tool no tool name function illustration 20
- Gen info 21
- Special tools 21
- Tool no tool name function illustration 21
- Gen info 22
- Special tools 22
- Tool no tool name function illustration 22
- Chapter 2 specifications 25
- Specifications 25
- General specifications 27
- Specifications 27
- Engine specifications 28
- Engine specifications 29
- Engine specifications 30
- Engine specifications 31
- Engine specifications 32
- Engine specifications 33
- Engine specifications 34
- Engine specifications 35
- Engine specifications 36
- Chassis specifications 37
- Chassis specifications 38
- Chassis specifications 39
- Chassis specifications 40
- Chassis specifications 41
- Electrical specifications 42
- Electrical specifications 43
- Electrical specifications 44
- A distance between flats b outside thread diameter 45
- A nut b bolt 45
- All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data 45
- Conversion table 45
- Conversion table general tightening torque specifications 45
- General tightening torque specifications 45
- General tightening torques 45
- Metric multiplier imperial 45
- Mm 0 3937 0 8 in 45
- Mm 0 3937 in 45
- Mm 10 mm 30 3 22 45
- Mm 12 mm 55 5 40 45
- Mm 14 mm 85 8 61 45
- Mm 16 mm 130 13 94 45
- Mm 6 mm 6 0 4 45
- Mm 8 mm 15 1 11 45
- Nm m kg ft lb 45
- This chart specifies tightening torques for stan dard fasteners with a standard iso thread pitch tightening torque specifications for spe cial components or assemblies are provided for each chapter of this manual to avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached unless otherwise specified tightening torque specifications require clean dry threads com ponents should be at room temperature 45
- Tightening torque 46
- Tightening torque 47
- Tightening torque 48
- Tightening torque 49
- Tightening torque 50
- Lubrication points and lubricant types 51
- Lubrication points and lubricant types 52
- Lubrication points and lubricant types 53
- Cooling system diagrams 54
- Cooling system diagrams 55
- Lubrication chart 56
- Lubrication diagrams 57
- Lubrication diagrams 58
- Lubrication diagrams 59
- Lubrication diagrams 60
- Cable routing 61
- Cable routing 62
- Cable routing 63
- Cable routing 64
- Cable routing 65
- Cable routing 66
- Cable routing 67
- È 1 è é 2 ê 3 4 5 67
- Cable routing 68
- Cable routing 69
- Cable routing 70
- Cable routing 71
- Cable routing 72
- Cable routing 73
- For f gb 73
- Cable routing 74
- Cable routing 75
- Cable routing 76
- Cable routing 77
- Cable routing 78
- Chapter 3 periodic checks and adjustments 80
- Chk adj 80
- Periodic checks and adjustments 80
- Chk adj 81
- Chk adj 82
- Introduction 82
- Introduction periodic maintenance and lubrication chart 82
- Note the annual checks must be performed every year except if a kilometer based maintenance is performed instead from 50 000 km repeat the maintenance intervals starting from 10 000 km items marked with an asterisk should be performed by a yamaha dealer as they require special tools data and technical skills 82
- Periodic checks and adjustments 82
- Periodic maintenance and lubrication chart 82
- This chapter includes all information necessary to perform recommended checks and adjustments if followed these preventive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter 82
- Chk adj 83
- 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 83
- Periodic maintenance and lubrication chart 83
- Chk adj 84
- Cowling and cover 84
- Chk adj 85
- Cowling and cover 85
- Chk adj 86
- Fuel tank 86
- Chk adj 87
- Fuel tank 87
- Chk adj 88
- Fuel tank 88
- Air filter case 89
- Chk adj 89
- Air filter case 90
- Chk adj 90
- Order job part q ty remarks 6 fuse box 2 1 7 rear mud guard 1 8 rear fender 1 for installation reverse the removal pro cedure 90
- 1110 9 17 3 91
- Air filter case 91
- Chk adj 91
- 1110 9 17 3 92
- Air filter case 92
- Chk adj 92
- Drive chain tensioner 1 14 air filter case joint clamp screw 1 loosen 15 air filter case 1 16 air filter case joint clamp 1 refer to installing the air filter case joint clamp 17 check hose 1 for installation reverse the removal pro cedure 92
- Order job part q ty remarks 12 air filter to crankcase breather cham ber hose 1 disconnect 92
- Air filter case 93
- Chk adj 93
- Adjusting the valve clearance 94
- Chk adj 94
- Engine 94
- Adjusting the valve clearance 95
- Chk adj 95
- Adjusting the valve clearance 96
- Chk adj 96
- Adjusting the exhaust gas volume 97
- Chk adj 97
- Adjusting the engine idling speed adjusting the throttle cable free play 98
- Chk adj 98
- Adjusting the throttle cable free play 99
- Chk adj 99
- Adjusting the throttle cable free play checking the spark plug 100
- Chk adj 100
- Checking the spark plug checking the ignition timing 101
- Chk adj 101
- Checking the ignition timing measuring the compression pressure 102
- Chk adj 102
- Chk adj 103
- Measuring the compression pressure 103
- Chk adj 104
- Measuring the compression pressure checking the engine oil level 104
- Checking the engine oil level changing the engine oil 105
- Chk adj 105
- Changing the engine oil 106
- Chk adj 106
- A slightly loosen the bleed bolt 1 b start the engine and keep it idling until engine oil starts to seep from the bleed bolt if no engine oil comes out after one minute turn the engine off so that it will not seize c check the engine oil passages the oil filter element and the oil pump for damage or leakage refer to oil pump in chapter 5 d start the engine after correcting the prob lem s and check the engine oil pressure again e tighten the bleed bolt to the specified torque 107
- Bleed bolt 5 nm 0 m kg 3 ft lb 107
- Changing the engine oil 107
- Check engine oil pressure 107
- Chk adj 107
- Install engine oil filler cap camshaft sprocket cover 107
- Start the engine warm it up for several min utes and then turn it off 15 check engine for engine oil leaks 16 check engine oil level refer to checking the engine oil level 107
- Adjusting the clutch cable free play 108
- Chk adj 108
- Checking the air filter element 109
- Chk adj 109
- Chk adj 110
- Checking the breather hose checking the exhaust system 111
- Chk adj 111
- Checking the coolant level checking the cooling system 112
- Chk adj 112
- Checking the cooling system changing the coolant 113
- Chk adj 113
- Changing the coolant 114
- Chk adj 114
- Changing the coolant 115
- Chk adj 115
- Changing the coolant 116
- Chk adj 116
- Adjusting the rear brake pedal 117
- Chassis 117
- Chk adj 117
- Adjusting the rear brake pedal checking the brake fluid level 118
- Chk adj 118
- Chk adj 119
- Adjusting the rear brake light switch checking the front and rear brake hoses 120
- Chk adj 120
- Bleeding the hydraulic brake system 121
- Chk adj 121
- Bleeding the hydraulic brake system adjusting the shift pedal 122
- Chk adj 122
- A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident therefore keep the drive chain slack within the speci fied limits 123
- A remove the bolt 1 b remove the shift pedal 2 c install the shift pedal at the correct position d install the bolt and then tighten it to the specified torque 123
- Adjust shift pedal position 123
- Adjusting the drive chain slack 123
- Adjusting the shift pedal adjusting the drive chain slack 123
- Caution 123
- Chk adj 123
- Place the motorcycle on a suitable stand so that the rear wheel is elevated 123
- Securely support the motorcycle so that there is no danger of it falling over 123
- Shift pedal bolt 16 nm 1 m kg 11 ft lb 123
- Spin the rear wheel several times and find the tightest position of the drive chain 123
- Stand the motorcycle on a level surface 123
- The drive chain slack must be checked at the tightest point on the chain 123
- Warning 123
- Adjusting the drive chain slack 124
- Chk adj 124
- Chk adj 125
- Lubricating the drive chain checking and adjusting the steering head 125
- Checking and adjusting the steering head 126
- Chk adj 126
- Checking and adjusting the steering head checking the front fork 127
- Chk adj 127
- Checking the front fork adjusting the rear shock absorber assembly 128
- Chk adj 128
- Checking the tires 129
- Chk adj 129
- Checking the tires 130
- Chk adj 130
- Checking the tires 131
- Chk adj 131
- Checking the tires checking and tightening the spokes 132
- Chk adj 132
- Chk adj 133
- Checking and charging the battery 134
- Chk adj 134
- Electrical system 134
- Checking and charging the battery 135
- Chk adj 135
- Checking and charging the battery 136
- Chk adj 136
- Charging method using a variable current voltage charger 137
- Checking and charging the battery 137
- Chk adj 137
- Charging method using a constant voltage charger 138
- Checking and charging the battery 138
- Chk adj 138
- Checking and charging the battery checking the fuses 139
- Chk adj 139
- Checking the fuses 140
- Chk adj 140
- Checking the fuses replacing the headlight bulb 141
- Chk adj 141
- Chk adj 142
- Replacing the headlight bulb adjusting the headlight beam 142
- A set the main switch to on b push the select button 2 and reset button 3 together for at least two seconds c when the hour digits start flashing push the reset button to set the hours d push the select button and the minute digits will start flashing e push the reset button to set the min utes f push the select button to start the clock 143
- After reconnecting the battery the clock indi cation is 1 00 and must be set to the correct time 143
- Chk adj 143
- Setting the digital clock 143
- Setting the digital clock 1 set digital clock 1 143
- Chapter 4 chassis 145
- Chassis 145
- Chassis 147
- Front wheel and brake disc 147
- Front wheel and brake disc 148
- Front wheel and brake disc 149
- Front wheel and brake disc 150
- Front wheel and brake disc 151
- Front wheel and brake disc 152
- A remove the brake disc b rotate the brake disc by one bolt hole c install the brake disc 153
- Adjust brake disc deflection 153
- Brake disc bolt 23 nm 2 m kg 17 ft lb loctit 153
- D measure the brake disc deflection e if out of specification repeat the adjustment steps until the brake disc deflection is within specification f if the brake disc deflection cannot be brought within specification replace the brake disc 153
- Front wheel and brake disc 153
- Installing the front wheel 1 lubricate oil seal lips 153
- Recommended lubricant lithium soap based grease 153
- Tighten the brake disc bolts in stages and in a crisscross pattern 153
- Front wheel and brake disc 154
- A install a balancing weight 1 onto the rim exactly opposite the heavy spot x 155
- A spin the front wheel b when the front wheel stops put an 155
- A turn the front wheel and make sure it stays at each position shown b if the front wheel does not remain stationary at all of the positions rebalance it 155
- Adjust front wheel static balance 155
- B turn the front wheel 90 so that the heavy spot is positioned as shown c if the heavy spot does not stay in that posi tion install a heavier weight d repeat steps b and c until the front wheel is balanced 155
- Check front wheel static balance 155
- Find front wheel s heavy spot 155
- Front wheel and brake disc 155
- Mark at the bottom of the wheel c turn the front wheel 90 so that the 155
- Mark at the bottom of the wheel f repeat steps d through f several times until all the marks come to rest at the same spot g the spot where all the marks come to rest is the front wheel s heavy spot x 155
- Mark is positioned as shown d release the front wheel e when the wheel stops put an 155
- Place the front wheel on a suitable balancing stand 155
- Start with the lightest weight 155
- Rear wheel brake disc and rear wheel sprocket 156
- Order job part q ty remarks 10 rear wheel 1 refer to removing the rear wheel and installing the rear wheel 11 spacer left 1 12 spacer right 1 13 brake caliper 1 refer to removing the rear wheel and installing the rear wheel 14 chain puller 2 for installation reverse the removal pro cedure 157
- Rear wheel brake disc and rear wheel sprocket 157
- Rear wheel brake disc and rear wheel sprocket 158
- Rear wheel brake disc and rear wheel sprocket 159
- Rear wheel brake disc and rear wheel sprocket 160
- Rear wheel brake disc and rear wheel sprocket 161
- Rear wheel brake disc and rear wheel sprocket 162
- A remove the self locking nuts and the rear wheel sprocket b clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c install the new rear wheel sprocket 163
- Checking and replacing the rear wheel sprocket 1 check rear wheel sprocket more than 1 4 tooth a wear replace the rear wheel sprocket bent teeth replace the rear wheel sprocket 163
- Installing the rear wheel 1 lubricate wheel axle oil seal lips 163
- Rear wheel brake disc and rear wheel sprocket 163
- Rear wheel sprocket self locking nut 69 nm 6 m kg 50 ft lb 163
- Recommended lubricant lithium soap based grease 163
- Replace rear wheel sprocket 163
- Tighten the self locking nuts in stages and in a crisscross pattern 163
- Rear wheel brake disc and rear wheel sprocket 164
- Front and rear brakes 165
- Front and rear brakes 166
- Front and rear brakes 167
- Front and rear brakes 168
- Front and rear brakes 169
- Front and rear brakes 170
- Front and rear brakes 171
- Front and rear brakes 172
- Front and rear brakes 173
- Front and rear brakes 174
- Front and rear brakes 175
- Front and rear brakes 176
- Front and rear brakes 177
- Front and rear brakes 178
- Front and rear brakes 179
- Front and rear brakes 180
- Front and rear brakes 181
- 2 3 new 182
- Front and rear brakes 182
- Front and rear brakes 183
- Front and rear brakes 184
- Front and rear brakes 185
- Front and rear brakes 186
- Front and rear brakes 187
- Front and rear brakes 188
- Front and rear brakes 189
- Front and rear brakes 190
- Front and rear brakes 191
- Front and rear brakes 192
- Front and rear brakes 193
- Front and rear brakes 194
- Front and rear brakes 195
- Front and rear brakes 196
- Front fork 197
- Cap bolt 1 loosen 8 lower bracket pinch bolt 2 loosen 198
- Front fork 198
- Front fork leg 1 xt660r 10 front fork leg 1 xt660x for installation reverse the removal pro cedure 198
- Order job part q ty remarks 6 upper bracket pinch bolt 2 loosen refer to removing the front fork legs and installing the front fork legs 198
- Front fork 199
- Front fork 200
- Front fork 201
- Front fork 202
- Front fork 203
- Front fork 204
- Front fork 205
- Front fork 206
- Front fork 207
- Front fork 208
- Handlebar 209
- Handlebar 210
- Handlebar 211
- Handlebar 212
- Handlebar 213
- Handlebar 214
- Steering head 215
- Order job part q ty remarks 11 bearing cover 1 12 upper bearing 1 refer to installing the steering head 13 lower bearing 1 14 upper bearing outer race 1 15 lower bearing outer race 1 16 dust seal 1 for installation reverse the removal pro cedure 216
- Steering head 216
- Steering head 217
- Steering head 218
- Steering head 219
- Rear shock absorber assembly 220
- Rear shock absorber assembly 221
- Rear shock absorber assembly 222
- Rear shock absorber assembly 223
- Rear shock absorber assembly 224
- Rear shock absorber assembly 225
- 15 17 18 18 226
- Drive chain guard 1 8 nut lock washer 1 1 9 drive sprocket 1 226
- Order job part q ty remarks removing the swingarm and drive chain remove the parts in the order listed 226
- Rear wheel refer to rear wheel brake disc and rear wheel sprocket 1 right side heel plate 1 2 brake master cylinder 1 3 rear brake light switch 1 4 right footrest brake pedal assembly 1 5 left side heel plate 1 6 drive sprocket cover 1 refer to removing the drive sprocket and installing the swingarm 226
- Swingarm and drive chain 226
- 15 17 18 18 227
- Bearing 2 16 spacer 1 17 spacer 1 18 oil seal bushing 2 2 19 drive chain 1 refer to removing the drive chain for installation reverse the removal pro cedure 227
- Order job part q ty remarks 10 nut washer bolt 1 1 1 refer to removing the drive sprocket and installing the swingarm 11 cap pivot shaft nut pivot shaft 2 1 1 227
- Refer to installing the swing arm 227
- Swingarm 1 refer to removing the swingarm and installing the swingarm 13 drive chain guide 1 14 dust cover oil seal 2 2 227
- Swingarm and drive chain 227
- A measure the tightening torque of the pivot shaft nut 228
- B measure the swingarm side play è by mov ing the swingarm from side to side c if the swingarm side play is out of specifica tion check the spacers bearings and dust covers 228
- D check the swingarm vertical movement é by moving the swingarm up and down if swingarm vertical movement is not smooth or if there is binding check the spacers bearings and dust covers 228
- Measure swingarm side play swingarm vertical movement 228
- Pivot shaft nut 92 nm 9 m kg 66 ft lb 228
- Place the motorcycle on a suitable stand so that the rear wheel is elevated 228
- Remove swingarm shaft nut pivot shaft swingarm 228
- Removing the swingarm 1 stand the motorcycle on a level surface 228
- Securely support the motorcycle so that there is no danger of it falling over 228
- Swingarm and drive chain 228
- Swingarm side play at the end of the swingarm 1 mm 0 4 in 228
- Warning 228
- Swingarm and drive chain 229
- Swingarm and drive chain 230
- Swingarm and drive chain 231
- Swingarm and drive chain 232
- Swingarm and drive chain 233
- Chapter 5 engine 236
- Engine 236
- Engine 240
- Engine removal 240
- Engine removal 241
- Engine removal 242
- Engine removal 243
- Engine removal 244
- Engine removal 245
- Engine removal 246
- Cylinder head 247
- Order job part q ty remarks removing the cylinder head remove the parts in the order listed engine refer to engine removal timing mark accessing screw crank shaft end accessing screw refer to adjusting the valve clearance in chapter 3 1 spark plug 1 2 camshaft sprocket cover o ring 1 1 3 tappet cover o ring 2 2 4 air cut off valve outlet pipe 1 5 gasket 1 6 oil delivery pipe 1 1 7 timing chain tensioner cap bolt 1 refer to removing the cylinder head and installing the cylin der head 247
- Timing chain tensioner gasket 1 1 9 camshaft sprocket 1 10 cylinder head 1 247
- Cylinder head 248
- Order job part q ty remarks 11 cylinder head gasket 1 12 dowel pin 2 for installation reverse the removal pro cedure 248
- Cylinder head 249
- Cylinder head 250
- Cylinder head 251
- Cylinder head 252
- Cylinder head 253
- Cylinder head 254
- Rocker arms and camshaft 255
- Bearing 1 256
- For installation reverse the removal pro cedure 256
- Order job part q ty remarks 7 decompressor lever pin 1 refer to removing the rocker arms and camshaft and installing the camshaft and rocker arms 256
- Rocker arms and camshaft 256
- Rocker arms and camshaft 257
- Rocker arms and camshaft 258
- Rocker arms and camshaft 259
- Rocker arms and camshaft 260
- Rocker arms and camshaft 261
- Valves and valve springs 262
- Valves and valve springs 263
- Valves and valve springs 264
- Valves and valve springs 265
- Valves and valve springs 266
- Valves and valve springs 267
- Valves and valve springs 268
- Valves and valve springs 269
- Valves and valve springs 270
- Cylinder and piston 271
- Cylinder and piston 272
- Cylinder and piston 273
- Cylinder and piston 274
- Cylinder and piston 275
- Cylinder and piston 276
- Cylinder and piston 277
- Cylinder and piston 278
- F f d c b 278
- Clutch 279
- Clutch 280
- 5 5 5 5 281
- Clutch 281
- Clutch 282
- Clutch 283
- Clutch 284
- Clutch 285
- Clutch 286
- Clutch 287
- Clutch 288
- New new 289
- Oil pump 289
- Order job part q ty remarks removing the oil pump remove the parts in the order listed engine oil drain refer to checking and changing the engine oil in chapter 3 coolant drain refer to changing the coolant in chapter 3 water pump assembly refer to water pump in chapter 6 clutch cable holder clutch housing refer to clutch right footrest brake pedal assembly refer to swingarm and drive chain in chapter 4 1 oil filter element cover 1 2 oil filter element 1 3 union bolt 3 4 oil delivery pipe 2 1 289
- New new 290
- Oil pump 290
- Oil pump 291
- Oil pump 292
- Oil pump 293
- Oil pump 294
- Balancer driven gear 295
- Balancer driven gear 296
- Balancer driven gear 297
- Balancer driven gear 298
- 8 7 13 11 299
- Shift shaft 299
- 8 7 13 11 300
- Shift shaft 300
- Shift shaft 301
- Starter clutch and a c magneto 302
- Starter clutch and a c magneto 303
- Starter clutch and a c magneto 304
- Starter clutch and a c magneto 305
- Starter clutch and a c magneto 306
- Starter clutch and a c magneto 307
- Crankcase 308
- Crankcase 309
- Order job part q ty remarks 5 lead holder 2 6 crankcase right 1 refer to separating the crank case 7 crankcase left 1 8 dowel pin o ring 1 1 9 dowel pin 2 10 oil strainer 1 11 oil delivery pipe 3 1 12 o ring 2 for installation reverse the removal pro cedure 309
- Crankcase 310
- Crankcase 311
- Crankcase 312
- Crankcase 313
- Crankcase 314
- Crankshaft 315
- Crankshaft 316
- Crankshaft 317
- Transmission 318
- Transmission 319
- Transmission 320
- Transmission 321
- Transmission 322
- Transmission 323
- Chapter 6 cooling system 325
- Cooling system 325
- Cooling system 327
- New new 327
- Radiator 327
- New new 328
- Radiator 328
- Radiator 329
- Radiator 330
- Thermostat 331
- Thermostat 332
- Thermostat 333
- Water pump 334
- Water pump 335
- Water pump 336
- Water pump 337
- Water pump 338
- Water pump 339
- Water pump 340
- Chapter 7 fuel injection system 342
- Fuel injection system 342
- 2 3 4 5 6 7 8 9 0 a 344
- B c d e f g h i j 344
- Fuel injection system 344
- Crankshaft position sensor 3 neutral switch 4 main switch 6 battery 7 main fuse 0 fuel injection system fuse d engine stop switch i fuel injection system relay j sidestand switch k fuel pump l ecu m ignition coil n spark plug o fuel injector p air induction system solenoid q intake air temperature sensor r coolant temperature sensor s speed sensor t throttle position sensor u intake air pressure sensor v lean angle cut off switch y multifunction meter engine trouble warning light v ignition fuse 345
- Fuel injection system 345
- Wiring diagram 345
- Fuel injection system 346
- Alternate operation control fail safe action if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven the ecu illuminates the engine trouble warning light and it provides the engine with alternate operating instructions according to the malfunction when an abnormal signal is received from a sensor the ecu processes the specified values that are programmed for each sensor in order to provide the engine with the alternate operating instruc tions that enable the engine to continue to operate or stop operating depending on the conditions the ecu applies the fail safe actions in two ways one in which the sensor output is set to a pre scribed value and the other in which the ecu directly operates an actuator details on the fail safe actions are given in the table below 347
- Checking for a defective engine trouble warning light bulb the engine trouble warning light comes on for 1 seconds after the main switch is turned to on or when the start switch is pushed if the warning light does not come on under these conditions the warning light bulb may be defective 347
- Fail safe action table self diagnostic function 347
- Fuel injection system 347
- Communication error with the meter 348
- Fuel injection system 348
- Fuel injection system 349
- Troubleshooting chart 349
- Fuel injection system 350
- Fuel injection system 351
- Diagnostic monitoring code table 352
- Fuel injection system 352
- Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively if it is not possible to check the intake air temperature use the ambient temperature as reference 353
- Diagnostic mode table switch the meter display from the regular mode to the diagnostic mode to switch the display refer to diagnostic mode 353
- Fuel injection system 353
- Fuel injection system 354
- Fuel injection system 355
- Troubleshooting details this section describes the countermeasures per fault code number displayed on the meter check and service the items or components that are the probable cause of the malfunction following the order in the troubleshooting chart after the checking and servicing the malfunctioning part reset the meter display refer to restore method fault code no fault code number displayed on the meter when the engine failed to work normally refer to diagnostic monitoring code table diagnostic code no diagnostic code number to be used when the diagnostic mode is operated refer to diagnos tic mode 355
- Fuel injection system 356
- Fuel injection system 357
- Fuel injection system 358
- Fuel injection system 359
- Warning 359
- Fuel injection system 360
- Fuel injection system 361
- Negative tester probe black white 2 361
- Fuel injection system 362
- Fuel injection system 363
- Fuel injection system 364
- Fuel injection system 365
- Throttle body assembly 366
- Throttle body assembly 367
- Throttle body assembly 368
- A disconnect the injection wire harness cou pler from the fuel injector b connect the pocket tester ω 1 to the fuel injector terminal as shown 369
- A wash the throttle body in a petroleum based solvent 369
- B blow out all of the passages with com pressed air 369
- C measure the fuel injector resistance out of specification replace the fuel injector 369
- Caution 369
- Checking the fuel injector 1 check fuel injector damage replace 2 check fuel injector resistance 369
- Checking the throttle body 1 check throttle body cracks damage replace the throttle body 2 check fuel passages obstructions clean 369
- Do not use any caustic carburetor cleaning solution 369
- Fuel injector resistance 12 ω at 20 c 68 f 369
- Positive tester probe red black 1 negative tester probe red blue 2 369
- Throttle body assembly 369
- Throttle body assembly 370
- Throttle body assembly 371
- Throttle body assembly 372
- Throttle body assembly 373
- A connecting the throttle position sensor cou pler to the wire harness b connect the digital circuit tester to the throt tle position sensor 374
- Adjust throttle position sensor angle 374
- C measure the throttle position sensor volt age d adjust the throttle position sensor angle so the measured voltage is within the specified range 374
- Digital circuit tester 90890 03174 374
- E after adjusting the throttle position sensor angle tighten the throttle position sensor screws 374
- Positive tester probe yellow terminal 1 negative tester probe black blue terminal 2 374
- Throttle body assembly 374
- Throttle position sensor resis tance 0 5 1 k ω at 20 c 68 f yellow black blue 374
- Throttle position sensor voltage 0 3 0 3 v yellow black blue 374
- Air induction system 375
- Air induction system 376
- Air induction system diagrams 376
- Air induction system 377
- Air induction system 378
- Air induction system 379
- Chapter 8 electrical system 381
- Electrical system 381
- Electrical components 383
- Electrical system 383
- P q s r 383
- Electrical components 384
- Checking switch continuity 385
- Checking the switches 387
- Eas00731 387
- R w l w 387
- Checking the switches 388
- Checking the bulbs and bulb sockets 389
- Checking the bulbs and bulb sockets 390
- A disconnect the meter assembly coupler meter assembly end 391
- A install a good bulb into the bulb socket b connect the pocket tester probes to the respective leads of the bulb socket c check the bulb socket for continuity if any of the readings indicate no continuity replace the bulb socket 391
- Check each bulb socket for continuity in the same manner as described in the bulb section however note the following 391
- Checking the bulbs and bulb sockets 391
- Checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets 1 check bulb socket for continuity with the pocket tester no continuity replace 391
- Checking the leds the following procedures applies to all of the leds 1 check led for proper operation improper operation replace 391
- Pocket tester 90890 03112 391
- B connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown 392
- Checking the bulbs and bulb sockets 392
- Continuity 392
- Immobilizer system indicator led connect the pocket tester k ω 1 to the meter coupler 392
- No conti nuity 392
- Positive tester probe black white negative tester probe green blue 392
- Positive tester probe green blue negative tester probe black white 392
- Checking the bulbs and bulb sockets 393
- Circuit diagram 394
- Crankshaft position sensor 4 main switch 6 battery 7 main fuse d engine stop switch l ecu m ignition coil n spark plug v lean angle cut off switch v ignition fuse 394
- Ignition system 394
- Ignition system 395
- Ignition system 396
- G w l y 397
- Ignition system 397
- Ignition system 398
- Circuit diagram 399
- E start switch g relay unit h starting circuit cut off relay j sidestand switch j clutch switch v ignition fuse 399
- Electric starting system 399
- Neutral switch 4 main switch 6 battery 7 main fuse 8 starter relay 9 starter motor d engine stop switch 399
- Electric starting system 400
- Electric starting system 401
- Electric starting system 402
- Electric starting system 403
- Electric starting system 404
- Starter motor 405
- Starter motor 406
- Starter motor 407
- Starter motor 408
- New new 409
- Starter motor 409
- Charging system 410
- Circuit diagram 410
- Charging system 411
- Charging system 412
- Circuit diagram 413
- Lighting system 413
- Main switch 6 battery 7 main fuse l ecu high beam indica tor light b headlight relay f pass switch g dimmer switch l headlight t auxiliary light u tail brake light x headlight fuse y parking lighting fuse 413
- Lighting system 414
- Lighting system 415
- Lighting system 416
- Lighting system 417
- Circuit diagram 419
- Signaling system 419
- Signaling system 420
- Signaling system 421
- Signaling system 422
- Signaling system 423
- Signaling system 424
- Signaling system 425
- Signaling system 426
- Signaling system 427
- Signaling system 428
- Signaling system 429
- Signaling system 430
- Circuit diagram 431
- Cooling system 431
- Main switch 6 battery 7 main fuse b radiator fan motor fuse l ecu q radiator fan motor relay r radiator fan motor v ignition fuse 431
- Cooling system 432
- Cooling system 433
- Circuit diagram 434
- Immobilizer system 434
- Main switch 6 battery 7 main fuse a backup fuse immobilizer unit meter assembly l ecu y multifunction meter a immobilizer system indicator light v ignition fuse z immobilizer unit 434
- Immobilizer system 435
- Accessory locks include the seat lock fuel tank cap and helmet holder 436
- Check that the engine can be started 3 register the standard keys refer to standard key registration 436
- Code re registering key registration when the immobilizer unit or ecu is replaced the code re registering key must be re registered 436
- Immobilizer system 436
- Key code registration the replacement of parts or code registration of a code re registering key or standard key may be required in the following conditions 436
- Note check that the immobilizer system indicator light comes on for 1 second then goes off when the indicator light goes off the code re registering key has been registered 436
- Note each standard key is registered during production therefore registering the keys at purchase is not necessary 436
- Parts to replace replacing a lost key or system malfunction 436
- Replace as a set with the main switch 436
- To register a code re registering key 1 set the main switch to on with the code re registering key 436
- Immobilizer system 437
- Check that the engine can be started with the two registered standard keys 438
- Immobilizer system 438
- Standard key code voiding method 438
- Standard key registration 438
- Voiding a standard key code if a registered standard key has been lost and you want to disable its use register a new standard key or re register the other standard key for registration of a standard key refer to standard key registration standard key registration erases the stored standard key codes from memory therefore the lost standard key is disabled 438
- Example multifunction code 52 439
- Immobilizer system 439
- Immobilizer system indicator light malfunction code indication digits of 10 on for 1 second and off for 1 seconds digits of 1 on for 0 second and off for 0 second 439
- Light off 439
- Light on 439
- Self diagnosis malfunction codes when a system malfunction occurs the malfunction code number is displayed on the multifunction display and is indicated by the immobilizer system indicator light flash patterns 439
- Immobilizer system 440
- Immobilizer system 441
- Immobilizer system 442
- Immobilizer system 443
- Immobilizer system 444
- When the main switch is set to on the immobilizer system indicator light flashes after 1 sec ond check if metal or other immobilizer system keys exists near the immobilizer unit if found remove the metal or keys and then check the condition again 444
- Self diagnosis 445
- Before troubleshooting remove the following part s 1 seat 2 side panels left and right 3 fuel tank side covers left and right 4 fuel tank troubleshoot with the following special tool s 446
- Check 1 fuel sender thermistor 446
- Check the led of the fuel level warning light refer to checking the bulbs and bulb sockets is the fuel level warning light led ok 446
- Check the wire harness for continuity refer to circuit diagram is the wire harness ok 446
- Fuel level warning light led 446
- Fuel sender thermistor circuit diagram 446
- Pocket tester 90890 03112 446
- Repair or replace the wire harness 446
- Replace the meter assembly 446
- Self diagnosis 446
- The fuel level warning light starts to indi cates the self diagnosis sequence 446
- Troubleshooting 446
- Wire harness 446
- Yes no 446
- Self diagnosis 447
- Chapter 9 troubleshooting 450
- Trbl shtg 450
- Troubleshooting 450
- Trbl shtg 451
- Starting failures 452
- Trbl shtg 452
- Troubleshooting 452
- Incorrect engine idling speed 453
- Starting failures incorrect engine idling speed 453
- Trbl shtg 453
- Faulty clutch 454
- Faulty gear shifting 454
- Poor medium and high speed performance 454
- Poor medium and high speed performance faulty gear shifting faulty clutch 454
- Trbl shtg 454
- Overcooling 455
- Overheating 455
- Overheating overcooling poor braking performance 455
- Poor braking performance 455
- Trbl shtg 455
- Faulty front fork legs 456
- Faulty front fork legs unstable handling 456
- Trbl shtg 456
- Unstable handling 456
- Faulty lighting or signaling system 457
- Trbl shtg 457
- Xt660r s xt660x s 2004 wiring diagram 458
- F g h i 462
- M n o p 462
- Wiring diagram 462
- Xt660r s xt660x s 2004 wiring diagram 462
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