User manual YAMAHA XT660R

[. . . ] 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. [. . . ] Refer to "CHECKING THE VALVE SEATS". Pour a clean solvent a into the intake and exhaust ports. Check that the valves properly seal. _ MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM NOTE: There should be no leakage at the valve seat 1. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. Remove: valve cotters NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2. _ Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-01243 5 - 24 VALVES AND VALVE SPRINGS 3. _ ENG Remove: valve spring retainer 1 valve spring 2 valve stem seal 3 valve spring seat 4 valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. Measure: valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a Valve stem diameter b Out of specification Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0. 010 ~ 0. 037 mm (0. 0004 ~ 0. 0015 in) <Limit>: 0. 08 mm (0. 0031 in) Exhaust 0. 025 ~ 0. 052 mm (0. 0010 ~ 0. 0020 in) <Limit>: 0. 10 mm (0. 0039 in) 5 - 25 VALVES AND VALVE SPRINGS 2. Replace: valve guide ENG NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 C (212 F) in an oven. _ MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Remove the valve guide with the valve guide remover 1. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance. NOTE: After replacing the valve guide, reface the valve seat. _ Valve guide remover (6) 90890-04064 Valve guide installer (6) 90890-04065 Valve guide reamer (6) 90890-04066 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. Eliminate: carbon deposits (from the valve face and valve seat) 4. Check: valve face Pitting/wear Grind the valve face. valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve. Measure: valve margin thickness a Out of specification Replace the valve. Valve margin thickness 0. 80 ~ 1. 20 mm (0. 0315 ~ 0. 0472 in) 5 - 26 VALVES AND VALVE SPRINGS ENG 6. Measure: valve stem runout Out of specification Replace the valve. NOTE: When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the valve stem seal. _ Valve stem runout 0. 010 mm (0. 0004 in) EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. Eliminate: carbon deposits (from the valve face and valve seat) 2. Check: valve seat Pitting/wear Replace the cylinder head. [. . . ] 9-3 CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 OVERHEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]