🏷️ Basic Information

Make:

Yamaha

Model:

XT 660 R

Year Start:

2004

Year End:

2008

Chassis Code:

Often referred to by internal Yamaha codes or VIN prefixes, specific codes for this model range are detailed within the manual.

Engine Code:

Commonly the 3YF designation for the XT660R engine.

👋 Introduction

Market Position:

The Yamaha XT660 R is a versatile dual-sport motorcycle, appealing to riders seeking adventure, commuting, and light off-road capabilities. It sits in the mid-weight adventure bike segment.

Competitors:

Competitors at the time included models like the KTM 640 Adventure, Honda XR650L, and potentially the Suzuki DR650SE.

Key Features:

Robust single-cylinder engine, long-travel suspension, rugged construction, capable on and off-road, fuel injection.

📋 Manual Details

Territory:

Global coverage for models sold between 2004-2008. Specific regional variations may be noted.

Page Count:

Estimated 400-600 pages (typical for comprehensive service manuals).

Manual Type:

Service and Repair Manual

Language:

Primarily English, with potential for localized diagrams or specific terminology.

Format:

Digital (PDF) - Searchable, printable.

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the single-cylinder, liquid-cooled, 4-stroke engine.

Fuel System:

Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, diagnostic codes.

Ignition System:

CDI unit, ignition coils, spark plug specifications, timing checks.

Cooling System:

Radiator, coolant, fan operation, thermostat, water pump, troubleshooting leaks.

Exhaust System:

Catalytic converter, mufflers, lambda sensor (oxygen sensor).

Transmission:

Clutch operation, gearbox disassembly, gear selection, lubrication, maintenance.

Chassis And Frame:

Frame inspection, steering head bearings, swingarm, rear shock absorber linkage and adjustment.

Suspension Front:

Front fork (telescopic, upside-down), oil levels, seals, damping adjustments, spring preload.

Suspension Rear:

Monoshock absorber, linkage system, adjustment procedures, spring preload, damping.

Brakes Front:

Brake caliper, master cylinder, brake lines, disc inspection and replacement, pad wear, bleeding procedures.

Brakes Rear:

Brake caliper, master cylinder, brake lines, disc inspection and replacement, pad wear, bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting, horn, starter motor.

Instrumentation And Controls:

Dashboard, switches, throttle control, brake levers, clutch lever.

Wheels And Tires:

Wheel bearing inspection, tire pressure recommendations, rim maintenance.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks.

Troubleshooting Diagnostics:

Step-by-step diagnostic procedures for common and uncommon issues, error code interpretation.

Engine Rebuild:

Detailed instructions for engine overhaul, including piston, rings, cylinder, valve train, and crankshaft procedures.

Suspension Overhaul:

Fork seal replacement, rear shock absorber service, linkage bearing replacement.

Brake System Service:

Bleeding brakes, replacing pads and discs, caliper and master cylinder overhaul.

Electrical Troubleshooting:

Using wiring diagrams to diagnose and repair electrical faults, component testing.

Fuel System Cleaning:

Cleaning fuel injectors, throttle body, and fuel filter.

Wheel And Tire Replacement:

Tire mounting and balancing, wheel bearing service.

Depth:

Comprehensive from basic owner maintenance to advanced engine and electrical system diagnostics and repair.

Diagnostic Tools:

Information on required special tools and diagnostic equipment (e.g., multimeter, torque wrench).

Torque Specifications:

Detailed torque specifications for all fasteners, critical for safe and proper assembly.

Tolerances And Clearances:

Engine component clearances (piston-to-cylinder, valve clearances), bearing tolerances.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High resolution, ensuring clarity of diagrams and text for printing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Searchability:

Fully text-searchable PDF for quick information retrieval.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Engine Oil Capacity:

Approx. 1.7 L (with oil filter change)

Horsepower:

Approximately 48 PS (35.3 kW) @ 6,000 rpm (EU specification, varies by region).

Torque:

Approximately 6.0 kgf-m (59 Nm) @ 5,250 rpm (EU specification).

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves

Fuel Type:

Unleaded gasoline (Octane rating typically 91 RON or higher)

Fuel Tank Capacity:

15 Liters (approx.)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Gear Ratios:

Specific gear ratios for each speed are detailed in the manual.

Transmission Oil Type:

Yamalube 4 (or equivalent API SG, SAE 10W-40) or similar motorcycle-specific gear oil.

📐 Dimensions

Length:

Approx. 2,230 mm

Width:

Approx. 850 mm

Height:

Approx. 1,230 mm

Seat Height:

Approx. 875 mm

Wheelbase:

Approx. 1,490 mm

Ground Clearance:

Approx. 260 mm

Dry Weight:

Approx. 170 kg

Wet Weight:

Approx. 182 kg (fully fueled and ready to ride, approximate)

Gross Vehicle Weight Rating:

Detailed in manual, typically around 330-350 kg.

🛡️ Safety Features

Safety Ratings:

Not typically rated by formal organizations like NHTSA for motorcycles; safety relies on rider skill and adherence to maintenance.

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Lighting:

Halogen headlight, LED taillight, turn signals for visibility.

Frame Construction:

Robust steel frame designed for durability and stability.

Ergonomics:

Upright riding position and wide handlebars for control and comfort.

💡 Technology Features

Infotainment Features:

Basic instrumentation including speedometer, tachometer, odometer, trip meter, fuel gauge, and warning lights. No advanced infotainment systems.

Driver Assistance Features:

No electronic rider aids like ABS or traction control are standard on this model. Focus is on mechanical simplicity and rider control.

Connectivity Features:

N/A - This model predates widespread motorcycle connectivity features.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-6,000 km or 6 months (refer to manual for exact specification and condition-based servicing).

Air Filter Cleaning Interval:

Inspect every 5,000 km, clean or replace as needed, more frequently in dusty conditions.

Spark Plug Replacement Interval:

Inspect at 10,000 km, replace as needed. Specific plug type and gap detailed in manual.

Valve Clearance Adjustment:

Typically every 10,000-20,000 km (check manual for exact interval and procedure).

Engine Oil Spec:

Yamalube 4 (or equivalent API SG, JASO MA, SAE 10W-40).

Coolant Spec:

High-quality ethylene glycol-based antifreeze with water (50:50 mix) for freezing protection and corrosion inhibition. Yamaha Coolant (or equivalent) recommended.

Brake Fluid Spec:

DOT 4 hydraulic brake fluid.

Common Issues:

Potential for clutch slave cylinder leaks (can be upgraded), occasional electrical connector issues, cam chain tensioner wear (depending on mileage and maintenance).

Oil Filter Part Number:

Generic part numbers vary by manufacturer (e.g., HiFloFiltro HF145, K&N KN-145), specific Yamaha OEM part number will be in the manual.

Air Filter Part Number:

Generic part numbers vary by manufacturer (e.g., BMC FM310/04), specific Yamaha OEM part number will be in the manual.

📚 Vehicle History

Brand Heritage:

Yamaha has a long and illustrious history in motorcycle design and manufacturing, particularly in off-road and dual-sport segments with its XT series dating back decades.

Model Evolution:

The XT660R is part of the evolution of Yamaha's XT line, which started with the legendary XT500. The XT660R introduced fuel injection and modern chassis design to the single-cylinder dual-sport concept.

Production Period:

The XT660 R model line was produced across various generations, with this specific manual covering the 2004-2008 iteration.

🏆 Awards & Recognition

Industry Recognition:

While specific awards for the 2004-2008 model year are not prominently advertised, the XT660 R line has been praised for its reliability and dual-purpose capability by motorcycle publications globally.