2004 Yamaha XT660R XT660X Service Manuals 5 files

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Basic Information Identification Make: Yamaha Model: XT660R / XT660X Year: 2004 Codes Engine Code: 102X (XT660R), 102X (XT660X) - Note: Yamaha often uses a single engine designation for variants within...

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Mots clés: 2004 Misc Motorcycle Motorcycles XT660R XT660X Yamaha

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Description

Basic Information
Identification
Make:	Yamaha
Model:	XT660R / XT660X
Year:	2004
Codes
Engine Code:	102X (XT660R), 102X (XT660X) - Note: Yamaha often uses a single engine designation for variants within a model range.
Chassis Codes:	XT660R: 3YF2, XT660X: 3YF4

Introduction
Market Position
Segment:	Dual-sport / Supermoto. The XT660R is a more off-road oriented dual-sport, while the XT660X is the Supermoto variant with street-focused wheels and tires.
Competitive Analysis
Competitors 2004:	Honda XR650L, Suzuki DR-Z400S, Kawasaki KLR650, KTM 640 LC4 Adventure.
Key Features
Engine Type:	Liquid-cooled, four-stroke, SOHC, four-valve single-cylinder. Known for strong low-to-mid range torque.
Fuel Delivery:	Electronic Fuel Injection (EFI) system, providing precise fuel metering and improved throttle response.
Chassis Design:	Steel diamond frame, offering a balance of rigidity and weight. XT660X features a slightly different chassis setup or suspension tuning for its supermoto role.

Manual Details
Coverage Areas
Languages Included:	English, French, German, Italian
Page Count
Estimated Total Pages:	Approximately 750-900 pages (estimated across all language files for comprehensive coverage).
Manual Type
Type:	Official Factory Service Manual (Workshop Manual)
Format
Digital Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanical:	Complete teardown and reassembly, cylinder head, valves, piston, crankshaft, lubrication system, cooling system (liquid-cooled).
Fuel System:	Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel pressure regulator, ECU control.
Ignition System:	Ignition control unit (ICU), ignition coil, spark plug, sensors (crankshaft position, camshaft position).
Transmission Drivetrain:	Clutch operation and adjustment, gearbox inspection and repair, final drive (chain and sprockets).
Electrical System:	Wiring diagrams, battery, charging system (stator, rectifier/regulator), starting system, lighting, instrumentation, sensors, ECU.
Chassis Suspension:	Front fork (upside-down telescopic), rear suspension (monoshock), swingarm, bearings, linkage.
Braking System:	Front disc brakes (dual piston caliper), rear disc brake (single piston caliper), hydraulic lines, master cylinders, bleeding procedures.
Wheels Tires:	Wheel bearings, tire fitting and balancing, rim specifications.
Bodywork Frame:	Frame inspection, seat, fuel tank, fenders, fairings, mounting points.
Cooling System:	Radiator, coolant, thermostat, fan operation, flushing and filling procedures.
Procedures Included
Routine Maintenance:	Oil changes, filter replacement, chain adjustment, lubrication points, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:	Diagnostic procedures for common faults, fault code interpretation (if applicable via diagnostic tools), electrical issue isolation.
Engine Repair:	Top-end rebuild, bottom-end overhaul, valve clearance adjustment, timing chain inspection.
Suspension Service:	Fork oil change, seal replacement, rear shock absorber inspection and adjustment.
Brake Service:	Brake pad replacement, caliper service, brake fluid flush and replacement, lever and pedal adjustment.
Electrical Diagnostics:	Wiring harness testing, component testing (stator, regulator, starter motor), troubleshooting electrical gremlins.
Fuel Injection Tuning:	Basic EFI system checks, sensor signal interpretation, ECU reset procedures.
Technical Depth
Level Of Detail:	Comprehensive, covering everything from routine maintenance to complete engine and chassis overhauls. Includes detailed diagrams, torque specifications, and diagnostic information.
Diagnostic Capability:	Provides methods for diagnosing electrical and mechanical faults, component testing procedures, and expected specifications for various sensors and systems.
Special Tools:	Lists required special tools and their part numbers for specific procedures (e.g., flywheel puller, clutch holding tool).

Manual Specifications
File Format
Format Details:	PDF files, typically optimized for digital viewing. Searchable text is a common feature in professionally produced PDFs.
Print Quality
Printability:	Designed for printing. High-resolution diagrams and clear text allow for easy reproduction of pages for workshop use.
Binding Type
Binding:	N/A (Digital format - PDF)
Paper Type
Paper Type:	N/A (Digital format - PDF)

Engine Specifications
Primary Engine
Engine Type:	Liquid-cooled, four-stroke, SOHC, four-valve single-cylinder
Displacement:	660 cc
Bore X Stroke:	100.0 mm x 84.0 mm
Compression Ratio:	10.0:1
Performance
Horsepower Est:	Approx. 47.3 hp @ 6000 rpm (claimed)
Torque Est:	Approx. 6.1 kgf·m (59.8 Nm) @ 5250 rpm (claimed)
Fuel System
Fuel System:	Electronic Fuel Injection (EFI) with Mikuni throttle body
Fuel Type:	Unleaded gasoline
Lubrication System
Oil Type:	Yamalube 4 (or equivalent SAE 10W-40 API SE, SF type or API SG, SH, SJ)
Oil Capacity W Filter:	2.60 L (2.75 US qt, 2.29 Imp qt)
Cooling System
Coolant Type:	High-quality ethylene glycol-based coolant with water (50:50 mixture)
Coolant Capacity:	1.80 L (1.90 US qt, 1.58 Imp qt)

Transmission
Standard
Transmission Type:	Constant mesh 5-speed
Clutch Type:	Wet, multiple-disc
Final Drive:	O-ring sealed chain
Features
Gear Ratios:	1st: 2.833, 2nd: 1.750, 3rd: 1.333, 4th: 1.100, 5th: 0.917
Transmission Oil Type:	Yamalube 4 (or equivalent SAE 10W-40 API SE, SF type or API SG, SH, SJ)
Transmission Oil Capacity
Oil Capacity:	0.70 L (0.74 US qt, 0.62 Imp qt)

Dimensions
Exterior
Length Xt660R:	2175 mm (85.6 in)
Width Xt660R:	825 mm (32.5 in)
Height Xt660R:	1215 mm (47.8 in)
Seat Height Xt660R:	865 mm (34.1 in)
Wheelbase Xt660R:	1460 mm (57.5 in)
Ground Clearance Xt660R:	245 mm (9.6 in)
Length Xt660X:	2125 mm (83.7 in)
Width Xt660X:	830 mm (32.7 in)
Height Xt660X:	1170 mm (46.1 in)
Seat Height Xt660X:	860 mm (33.9 in)
Wheelbase Xt660X:	1475 mm (58.1 in)
Weights
Wet Weight Xt660R:	182 kg (401.2 lbs) (approximate, with all fluids)
Wet Weight Xt660X:	183 kg (403.4 lbs) (approximate, with all fluids)
Fuel Capacity:	15 L (3.96 US qt, 3.30 Imp qt)
Reserve Fuel Capacity:	Approx. 3 L (0.79 US qt, 0.66 Imp qt)
Wheels Tires
Front Tire Size Xt660R:	90/90-21M/C 54S
Rear Tire Size Xt660R:	130/80-17M/C 65S
Front Tire Size Xt660X:	120/70ZR17M/C (58W) tubeless
Rear Tire Size Xt660X:	160/60ZR17M/C (69W) tubeless
Front Wheel Type:	Spoked (XT660R), Cast (XT660X)
Rear Wheel Type:	Spoked (XT660R), Cast (XT660X)

Safety Features
Ratings
Crash Test Ratings:	N/A (Motorcycles are not typically subjected to the same crash test protocols as cars.)
Active Features
Braking System:	Hydraulic dual disc front brake, hydraulic single disc rear brake. ABS was not a standard or common option for this model year.
Passive Features
Lighting:	Halogen headlight, LED taillight, standard turn signals.
Instrumentation:	Digital speedometer, analog tachometer, multi-function LCD display (fuel gauge, trip meters, clock).

Technology Features
Infotainment
Instrument Cluster:	Digital LCD display with speedometer, odometer, trip meters, fuel gauge, and clock. Analog tachometer.
Driver Assistance
ABS:	Not available on the 2004 model year as standard or a common factory option.
Connectivity
Diagnostic Ports:	Includes a diagnostic connector for accessing ECU data and fault codes, facilitating troubleshooting.

Maintenance
Service Intervals
First Service:	1000 km (600 miles) or 6 months, whichever comes first. Includes oil change, filter inspection, chain check, and general inspection.
Subsequent Intervals:	Every 4000 km (2500 miles) or 12 months for regular maintenance (oil change, filter inspection, chain lube/adjustment). Valve clearance checks typically every 10,000-12,000 km (6,000-7,500 miles).
Fluid Specifications
Engine Oil Viscosity:	SAE 10W-40
Brake Fluid Type:	DOT 4
Coolant Mixture:	50% Ethylene Glycol, 50% Distilled Water
Known Issues
Common Wear Items:	Clutch plates, chain and sprockets, brake pads, fork seals, wheel bearings due to typical usage for this type of motorcycle.
Potential Electrical Issues:	While generally reliable, issues with the rectifier/regulator or stator can occur with age and high mileage, as with many motorcycles. Regular battery maintenance is crucial.
Fuel Injection Maintenance:	Requires periodic cleaning of the throttle body and injectors, especially if poor fuel quality is used. The manual will detail procedures for this.

Vehicle History
Brand Heritage
Yamaha Motorcycle Division:	Yamaha Motor Company is renowned for its long history in motorcycle manufacturing, dating back to the YA-1 in 1955. Known for innovation, performance, and reliability across various motorcycle segments.
Model Evolution
Xt Series Legacy:	The XT series has a rich history in off-road and dual-sport motorcycles, starting with the legendary XT500. The XT660R and XT660X represent a modern interpretation, incorporating fuel injection and liquid cooling.
Production
Production Years:	The XT660 platform was introduced in the early 2000s and saw various iterations and updates. The 2004 model year is part of the initial generation.

Awards & Recognition
Recognitions
Motorcycle Press Reviews:	While specific awards for the 2004 model year might be elusive in widely publicized lists, the XT660 platform generally received positive reviews for its strong single-cylinder engine, versatility, and handling, particularly the XT660X in the supermoto category.