🏷️ Basic Information

Make:

Yamaha

Model:

XT-660

Year:

2004

Engine Type:

Single-cylinder, 4-stroke

Chassis Code:

Often designated by model variations, e.g., XT660R, XT660X, XT660Z (Ténéré)

👋 Introduction

Segment:

Dual-sport / Adventure motorcycle

Target User:

Riders seeking a versatile motorcycle capable of both on-road commuting and off-road exploration.

Key Competitors:

Honda Transalp, Suzuki V-Strom, Kawasaki KLR series, KTM LC4 series (depending on specific XT660 variant).

Engine Characteristics:

Torquey single-cylinder engine known for its reliability and manageable power delivery.

Versatility:

Adaptable for various riding conditions, from city streets to light trails.

Durability:

Yamaha's reputation for robust engineering and long-lasting components.

📋 Manual Details

Market Availability:

Global, with regional variations

Primary Audience:

Professional Technicians, Experienced DIY Mechanics

Estimated Page Count:

Typically 300-500+ pages (exact count may vary based on specific model variant and language)

Type:

Workshop Service Manual / Repair Manual

Language:

English (primary, as indicated by product description)

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine overhaul, internal components, cylinder head, piston, crankshaft, lubrication system, cooling system (if applicable).

Fuel System:

Fuel injection system (FI), fuel pump, injectors, throttle body, fuel tank, lines, emissions control.

Ignition System:

ECU (Engine Control Unit), ignition coils, spark plugs, wiring.

Transmission:

Gearbox internals, clutch operation, shift mechanism, lubrication.

Chassis:

Frame inspection, adjustments, disassembly and reassembly of frame components.

Suspension:

Front forks (disassembly, seal replacement, oil levels, damping adjustments), rear shock absorber (rebuild, adjustments).

Brakes:

Front and rear brake systems, caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, rotor inspection.

Electrical System:

Wiring diagrams, battery, charging system (alternator, rectifier/regulator), lighting, starter motor, instrumentation, sensors.

Cooling System:

Radiator, cooling fan (if applicable), coolant circulation, thermostat.

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if equipped), mounting hardware.

Wheels Tires:

Wheel bearing service, tire mounting and balancing, spoke inspection and tightening (for spoked wheels).

Bodywork:

Fairings, seat, fuel tank removal and installation, fenders, plastics.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, valve clearance checks and adjustments, chain maintenance.

Troubleshooting:

Diagnostic procedures for common and uncommon faults, error code interpretation (if applicable).

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly.

Rebuilds:

Detailed procedures for engine, transmission, and suspension component rebuilds.

Adjustments:

Carburetor/throttle body synchronization, idle speed adjustment, chain slack adjustment, suspension sag adjustment.

Technical Specifications:

Torque values, clearance measurements, fluid capacities, electrical resistances.

Depth:

Comprehensive, covering from basic maintenance to full engine and chassis rebuilds. Includes detailed diagrams and specifications.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely searchable text-based PDF, allowing for keyword searches.

Quality:

High-resolution images and diagrams for clarity. Designed for digital viewing and potentially printing.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

Typically 10Y or 38X for the 5-valve SOHC, fuel-injected unit.

Displacement:

659.7 cc (660 cc)

Bore X Stroke:

Approx. 100 mm x 84 mm

Compression Ratio:

Approximately 10.0:1

Valve Train:

SOHC, 5 valves per cylinder (3 intake, 2 exhaust)

Horsepower:

Approx. 47-48 HP @ 6,000 RPM (varies slightly by model and region)

Torque:

Approx. 57-60 Nm @ 5,250 RPM (varies slightly by model and region)

Fuel Delivery:

Electronic Fuel Injection (EFI) with Mikuni throttle body

Fuel Type:

Unleaded gasoline (91 RON or higher recommended)

Cooling Method:

Liquid-cooled

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multi-disc

Final Drive:

O-ring sealed chain drive

Gear Ratios:

Specific ratios available in the manual (e.g., 1st: 2.846, 2nd: 1.944, 3rd: 1.450, 4th: 1.150, 5th: 0.923)

📐 Dimensions

Length:

Varies by model variant (e.g., XT660R: ~2150 mm, XT660Z Ténéré: ~2245 mm)

Width:

Varies by model variant (e.g., XT660R: ~845 mm, XT660Z Ténéré: ~890 mm)

Height:

Varies by model variant (e.g., XT660R: ~1255 mm, XT660Z Ténéré: ~1390 mm)

Wheelbase:

Varies by model variant (e.g., XT660R: ~1475 mm, XT660Z Ténéré: ~1500 mm)

Dry Weight:

Approx. 160-170 kg (varies by model variant)

Wet Weight:

Approx. 176-187 kg (fully fueled, varies by model variant)

Fuel Tank Capacity:

Varies by model variant (e.g., XT660R: 15L, XT660Z Ténéré: 23L)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle safety ratings are typically not standardized like automotive)

Braking System:

Disc brakes front and rear. ABS was not standard on all 2004 models but became available on later iterations or specific variants.

Lighting:

Halogen headlight, LED taillight (model dependent).

Frame Construction:

Steel frame designed for strength and rigidity for dual-purpose riding.

💡 Technology Features

Instrumentation:

Digital LCD display including speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and indicator lights. Some models might feature an analog tachometer.

ABS:

Optional on some variants or later models, but not standard on the 2004 model year as a whole.

Charging Port:

Not typically fitted as standard from the factory in 2004, but can be added by the owner.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-6,000 km or 6 months, whichever comes first.

Oil Filter Change:

Every oil change.

Air Filter Cleaning:

Every 5,000-10,000 km, depending on riding conditions.

Valve Clearance Check:

Typically every 20,000-24,000 km.

Spark Plug Replacement:

Every 10,000-12,000 km (or as specified by plug type).

Engine Oil Type:

Yamaha's recommended high-quality 4-stroke motorcycle oil, typically SAE 10W-40 API SG or higher, JASO MA certified.

Engine Oil Capacity:

Approx. 2.1-2.4 liters with filter change (check manual for exact amount).

Coolant Type:

Permanent type antifreeze coolant, mixed with distilled water (50/50 ratio recommended).

Brake Fluid Type:

DOT 4

Fork Oil Type:

Yamaha recommended fork oil or equivalent SAE 10W (check manual for viscosity and level).

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.

Potential Engine Concerns:

Some early models experienced minor oil consumption issues or stator failures, though generally considered very reliable. Valve clearance adjustment is crucial for longevity.

Electrical Notes:

Regular checks of battery terminals and charging system output are recommended. Stator failure can lead to charging problems.

📚 Vehicle History

Yamaha Legacy:

Yamaha has a long history of producing reliable and innovative motorcycles, particularly in the dual-sport and adventure segments (e.g., XT500, Ténéré lineage).

Xt Series:

The XT-660 continues the legacy of the 'XT' line, which began with the legendary XT500, offering a blend of trail capability and road usability. The 660cc single-cylinder engine was a significant update for the series.

Production Years:

The XT-660 platform was introduced in the early 2000s and saw several variants (R, X, Z) produced for many years.

Manufacturing Location:

Primarily manufactured in Japan by Yamaha Motor Company.

🏆 Awards & Recognition

Market Reception:

Generally well-received for its versatility, reliability, and value proposition in the dual-sport segment.

Owner Satisfaction:

High owner satisfaction reported for long-term reliability and low running costs, particularly with proper maintenance.