Model Years Covered:
2004, 2005, 2006, 2007, 2008
Chassis Codes:
XT660R (often identified by specific VIN prefixes, not explicitly stated in product info), XT660X (often identified by specific VIN prefixes, not explicitly stated in product info)
Segment:
Dual-sport / Supermoto (XT660R is dual-sport, XT660X is motard-styled)
Target Audience:
Owners and mechanics seeking detailed information for maintenance, repair, and diagnostics of Yamaha XT660R and XT660X motorcycles.
Competitors:
Competes with other dual-sport and supermoto motorcycles from manufacturers like Honda (e.g., XR series), Kawasaki (e.g., KLR series), Suzuki (e.g., DR-Z series), and KTM (e.g., EXC series) in its displacement class.
Vehicle Focus:
Versatile performance for both on-road and light off-road (XT660R) or aggressive street riding (XT660X) with reliable single-cylinder engine technology.
Mechanical Systems:
Engine (internal components, tuning, diagnostics), Fuel System (injection, pumps, injectors), Ignition System, Cooling System, Lubrication System, Clutch, Transmission, Drive Train (chain, sprockets), Suspension (front forks, rear shock), Brakes (front and rear discs, calipers, master cylinders), Steering, Frame, Wheels, Tires
Electrical Systems:
Wiring Diagrams, Battery, Charging System (alternator, regulator/rectifier), Starting System (starter motor), Lighting (headlight, taillight, turn signals), Instrumentation, ECU (Engine Control Unit), EFI (Electronic Fuel Injection) System components, Sensors
Chassis Components:
Frame inspection and repair guidelines, swingarm, linkage (if applicable), footpegs, handlebars, and body panels.
Maintenance:
Routine service intervals, oil changes, filter replacements, spark plug replacement, chain adjustment and lubrication, brake fluid changes, coolant flushes, valve clearance checks and adjustments
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, error code interpretations (if applicable to EFI system)
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly. Includes engine rebuild procedures, transmission overhaul, suspension fork service, brake caliper servicing, and body panel removal/installation.
Electrical Diagnostics:
Troubleshooting of electrical faults, testing of sensors, starter motor, charging system components, and lighting circuits using multimeter readings and wiring diagrams.
Wheel Tire Service:
Information on tire inspection, replacement, wheel balancing, and spoke tensioning (for spoked wheels).
Depth:
Comprehensive. Covers from basic maintenance tasks to complete engine and component overhauls, advanced diagnostics, and electrical system troubleshooting. Suitable for both experienced DIY mechanics and professional technicians.
Torque Specifications:
Detailed torque specifications for all critical fasteners throughout the motorcycle, essential for proper assembly and preventing damage.
Special Tools:
Lists of Yamaha-specific or recommended special tools required for certain maintenance and repair procedures.
Type:
Four-stroke, liquid-cooled, SOHC, single-cylinder
Bore X Stroke:
100.0 mm x 84.0 mm
Compression Ratio:
10.0:1
Horsepower:
Approx. 47 hp (35 kW) @ 6000 rpm (specific figures may vary slightly by market and tuning)
Torque:
Approx. 60 Nm (44.3 lb-ft) @ 5250 rpm (specific figures may vary slightly by market and tuning)
Induction:
Electronic Fuel Injection (EFI) with dual throttle valves (likely Yamaha's YCC-T or similar system)
Fuel Type:
Unleaded gasoline
Type:
TCI (Transistor Controlled Ignition) or CDI (Capacitor Discharge Ignition) with electronic timing advance.
Length:
XT660R: Approx. 2,225 mm (87.6 in), XT660X: Approx. 2,175 mm (85.6 in) (specific figures available in manual)
Width:
XT660R: Approx. 850 mm (33.5 in), XT660X: Approx. 830 mm (32.7 in) (specific figures available in manual)
Height:
XT660R: Approx. 1,265 mm (49.8 in), XT660X: Approx. 1,175 mm (46.3 in) (specific figures available in manual)
Wheelbase:
XT660R: Approx. 1,475 mm (58.1 in), XT660X: Approx. 1,460 mm (57.5 in) (specific figures available in manual)
Ground Clearance:
XT660R: Approx. 215 mm (8.5 in) (specific figures available in manual)
Dry Weight:
XT660R: Approx. 163 kg (360 lbs), XT660X: Approx. 161 kg (355 lbs) (specific figures available in manual)
Wet Weight:
Approx. 182 kg (401 lbs) for XT660R (with all fluids and ready to ride, specific figures available in manual)
Fuel Capacity:
15 Liters (3.96 US gal)
Crash Safety:
N/A for motorcycles in the same way as cars. Focus is on handling, braking, and rider protection through chassis design.
Braking System:
Hydraulic disc brakes front and rear. XT660X typically features larger front disc. ABS was not a common factory option for these models in this era.
Suspension Stability:
Adjustable front telescopic forks and rear monoshock suspension provide stability and control across various surfaces.
Lighting:
Halogen headlight, LED taillight, amber turn signals for visibility.
Features:
Basic analogue tachometer with digital speedometer, LCD multi-function display (fuel gauge, trip meters, clock), warning lights.
Features:
ABS was not standard or widely available on these specific model years. Electronic fuel injection is the primary advanced technology for engine management.
Features:
No built-in Bluetooth or smartphone connectivity on these models. Connectivity is limited to mechanical and electrical interfaces.
System:
Electronic Fuel Injection (EFI) system with an Engine Control Unit (ECU) for precise fuel delivery and ignition timing.
Oil Change:
Every 6,000 km or 6 months (check manual for exact specifications and oil type).
Valve Clearance:
Typically at 20,000 km or 24,000 km intervals, or as specified in the manual.
Spark Plug Replacement:
Recommended replacement at 10,000 km or based on wear inspection. NGK CR9E or similar is a common fitment.
Chain Maintenance:
Lubricate and adjust chain every 1,000 km or more frequently under adverse conditions.
Engine Oil:
Yamalube 10W-40 or equivalent API SG or higher, JASO MA certified (check manual for precise viscosity and certification).
Engine Oil Capacity:
Approx. 2.4 Liters (with oil filter change).
Coolant:
Yamaha's premixed coolant or an equivalent ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid (ensure compatibility).
Common Faults:
Potential issues may include stator failures, voltage regulator/rectifier problems, starter clutch wear, and clutch slave cylinder leaks. The manual will provide diagnostic steps for these and other potential problems.
Maintenance Tips:
Regular cleaning of the EFI injectors and throttle body can help maintain optimal performance. Proper chain tension and lubrication are crucial for drivetrain longevity.
Yamaha Legacy:
Yamaha has a long-standing reputation for producing reliable and performance-oriented motorcycles, particularly in the dual-sport and off-road segments with its XT lineage dating back decades.
Xt660 Lineage:
The XT660 engine platform, originating from the TT600, evolved into the fuel-injected XT660R and XT660X, offering modern performance and efficiency in a versatile package. The R is the more traditional dual-sport, while the X is the motard version focused on street performance.
Manufacturing Location:
Yamaha motorcycles are typically manufactured in Japan, or at international facilities overseen by Yamaha Motor Company.
