User manual YAMAHA XT660X

[. . . ] 2004 XT660R(S) XT660X(S) 5VK1-AE1 SERVICE MANUAL EAS00000 XT660R(S)/XT660X(S) 2004 SERVICE MANUAL 2003 by MBK Industrie First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited. EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. [. . . ] Eliminate: combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: spark plug bore threads valve seats _ 2. Measure: cylinder head warpage Out of specification Resurface the cylinder head. Maximum cylinder head warpage 0. 03 mm (0. 0012 in) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 1 2 a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Place 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. _ LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5 - 11 CYLINDER HEAD EAS00212 ENG 2 1 3 3 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Check: tappet covers 1 camshaft sprocket cover 2 O-rings 3 Damage/wear Replace the defective part(s). EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: one-way cam operation Rough movement Replace the timing chain tensioner housing. Check: timing chain tensioner cap bolt copper washer New spring one-way cam gasket New timing chain tensioner rod Damage/wear Replace the defective part(s). Check: camshaft sprocket Wear/damage Replace the camshaft sprocket and timing chain as a set. a 1/4 of a tooth b Correct 1 Roller 2 Sprocket EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: dowel pins cylinder head gasket New 5 - 12 CYLINDER HEAD 2. Install: cylinder head washers New cylinder head bolts ENG NOTE: Lubricate the cylinder head bolt threads and muting surface with engine oil. Tighten: cylinder head bolts 1 = 135 mm (5. 31 in) = 145 mm (5. 71 in) 4 2 3 1 50 Nm (5. 0 m kg, 36 ft lb) 50 Nm (5. 0 m kg, 36 ft lb) 45 Nm (4. 5 m kg, 32 ft lb) 10 Nm (1. 0 m kg, 7. 2 ft lb) cylinder head bolts 2 T. T. R. R. 2 4 4 1 cylinder head bolts 3 cylinder head bolts 4 NOTE: Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages. _ T. Install: camshaft sprocket (onto the camshaft) NOTE: Make sure that the projection a on the decompressor lever is in the position shown in the illustration. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM c b a. Install the timing chain 1 onto the camshaft sprocket 2, then the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolts. NOTE: To install the camshaft sprocket sprocket, install the projection 3 on the camshaft sprocket into the slot a in the decompression lever. Make sure the "I" mark d on the camshaft sprocket with the stationary pointer e on the cylinder head. NOTE: When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible at the exhaust end of the chain. Align the projection on the camshaft with the slot in the camshaft sprocket. _ d 1 2 CAUTION: _ Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. Remove the wire from the timing chain. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6 New 3 2 New 1 5. Install: timing chain tensioner MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. [. . . ] 9-3 CLUTCH SLIPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 OVERHEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]