Model Variant:
XT660R (Dual-sport), XT660X (Supermoto)
Model Years Covered:
2004, 2005, 2006, 2007, 2008, 2009
Chassis Code:
XT660R: 5VK, XT660X: 10D
Market Position:
The Yamaha XT660R and XT660X occupy the dual-sport and supermoto segments respectively, appealing to riders seeking versatile, off-road capable or road-biased performance with a strong single-cylinder engine.
Competitive Analysis:
Competes with models like the KTM 640/690 Duke/Enduro, Honda XR650L, Suzuki DR650SE, and BMW F650GS/G650GS in their respective categories. The XT660 series is known for its robust build and torquey engine.
Key Features:
Liquid-cooled 4-stroke single-cylinder engine, robust chassis, capable suspension (especially the R model for off-road), fuel injection, and distinctive styling. The X model features more road-oriented suspension and tires.
Systems Covered:
Engine (Disassembly, Assembly, Tuning), Fuel System (Injection, Pumps, Injectors), Ignition System, Electrical System (Wiring Diagrams, Components), Chassis, Suspension (Front Forks, Rear Shock), Braking System (Front/Rear Discs, Calipers, Master Cylinders), Wheels, Tires, Frame, Bodywork, Lubrication, Cooling System, Exhaust System, Clutch, Transmission, Drive Chain, Controls, Instrumentation
Procedures Included:
Routine Maintenance (Oil Changes, Filter Replacements, Chain Adjustment), Troubleshooting Guides, Component Removal and Installation, Engine Rebuilding, Carburetor/Fuel Injection Adjustment, Electrical Diagnostics, Brake Service and Bleeding, Suspension Setup and Overhaul, Torque Specifications, Special Tool Requirements, Diagnostic Codes (if applicable)
Technical Depth:
Comprehensive: Covers everything from basic owner maintenance to complete engine overhauls and advanced electrical diagnostics. Suitable for DIY enthusiasts and professional technicians.
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 4-valve single-cylinder
Bore X Stroke:
100.0 mm x 84.0 mm
Compression Ratio:
10.0:1
Valve Train:
SOHC, 4 valves per cylinder
Horsepower Est:
Approx. 48 HP (36 kW) @ 6000 rpm
Torque Est:
Approx. 60 Nm (44 lb-ft) @ 5250 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI) with Mikuni throttle body (approx. 44mm)
Fuel Type:
Unleaded gasoline (91 RON or higher)
Oil Type Recommendation:
Yamalube 4 (SAE 20W-40) or equivalent motorcycle oil
Oil Capacity W Filter Change:
Approx. 2.1 Liters (2.2 US qt)
Cooling Method:
Liquid-cooled
Coolant Type:
Yamaha's recommended Yamalube coolant or a high-quality ethylene glycol-based coolant (50/50 mix with distilled water)
Transmission Type:
Constant mesh 5-speed
Clutch Type:
Wet, multiple-disc
Gear Ratios:
Specific ratios detailed in manual, typically focused on versatility for both models.
Transmission Oil Type:
Yamalube 4 (SAE 20W-40) or equivalent motorcycle oil
Transmission Oil Capacity:
Approx. 1.0 Liter (1.1 US qt)
Length Xt660R:
Approx. 2,235 mm (87.99 in)
Length Xt660X:
Approx. 2,190 mm (86.22 in)
Width Xt660R:
Approx. 830 mm (32.68 in)
Width Xt660X:
Approx. 825 mm (32.48 in)
Height Xt660R:
Approx. 1,175 mm (46.26 in)
Height Xt660X:
Approx. 1,120 mm (44.09 in)
Seat Height Xt660R:
Approx. 875 mm (34.45 in)
Seat Height Xt660X:
Approx. 870 mm (34.25 in)
Dry Weight Xt660R:
Approx. 163 kg (359 lbs)
Dry Weight Xt660X:
Approx. 167 kg (368 lbs)
Wet Weight Est Xt660R:
Approx. 180 kg (397 lbs) (with fluids)
Wet Weight Est Xt660X:
Approx. 184 kg (406 lbs) (with fluids)
Fuel Tank Capacity:
15 Liters (3.96 US gal)
Fuel Reserve:
Approx. 3 Liters (0.79 US gal)
Frame Type:
Diamond type, steel
Front Suspension Type:
Telescopic fork
Front Suspension Travel Xt660R:
Approx. 225 mm (8.86 in)
Front Suspension Travel Xt660X:
Approx. 140 mm (5.51 in)
Rear Suspension Type:
Swingarm (Monocross suspension)
Rear Suspension Travel Xt660R:
Approx. 200 mm (7.87 in)
Rear Suspension Travel Xt660X:
Approx. 120 mm (4.72 in)
Front Wheel Size Xt660R:
21 inch spoke wheel
Front Wheel Size Xt660X:
17 inch cast aluminum wheel
Rear Wheel Size Xt660R:
17 inch spoke wheel
Rear Wheel Size Xt660X:
17 inch cast aluminum wheel
Front Tire Size Xt660R:
90/90-21M/C 54S (Tube type)
Front Tire Size Xt660X:
120/70R17M/C 58W (Tubeless)
Rear Tire Size Xt660R:
130/80-17M/C 65S (Tube type)
Rear Tire Size Xt660X:
160/60R17M/C 69H (Tubeless)
Wheelbase Xt660R:
Approx. 1,495 mm (58.86 in)
Wheelbase Xt660X:
Approx. 1,460 mm (57.48 in)
Ground Clearance Xt660R:
Approx. 215 mm (8.46 in)
Ground Clearance Xt660X:
Approx. 175 mm (6.89 in)
Front Brake Type:
Hydraulic disc
Front Brake Rotor Diameter Xt660R:
300 mm
Front Brake Rotor Diameter Xt660X:
320 mm (wave style)
Rear Brake Type:
Hydraulic disc
Rear Brake Rotor Diameter:
245 mm
Safety Ratings:
N/A (Motorcycle safety is primarily assessed through design features and rider skill, not standardized crash test ratings like cars.)
Active Safety Features:
Effective braking systems (dual front discs on X, large single front disc on R), responsive suspension, and a stable chassis designed for the intended riding conditions of each model.
Passive Safety Features:
Robust frame construction, handlebar protection (often aftermarket), integrated lighting, and durable bodywork.
Infotainment System:
Basic instrumentation: Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, and indicator lights. No advanced infotainment features typical of modern touring or sportbikes.
Driver Assistance Features:
No electronic rider aids like traction control or ABS are standard on these models. Focus is on mechanical performance and rider input.
Lighting Type:
Halogen headlight, incandescent taillight and turn signals.
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first. Check manual for exact recommendation.
Oil Filter Replacement:
Recommended with every oil change.
Air Filter Cleaning Interval:
Every 5,000 km (3,000 miles) or 6 months. Replace as needed.
Spark Plug Inspection Replacement:
Inspect every 10,000 km (6,000 miles), replace as needed. Consult manual for specific plug type (e.g., CR8E).
Chain Lubrication Adjustment:
Lubricate every 1,000 km (600 miles) or after riding in wet conditions. Adjust chain slack every 5,000 km (3,000 miles).
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Known Issues:
Some common points of attention include: potential for stator failure, occasional fuel pump issues, and ensuring proper maintenance of the single-cylinder engine's vibration characteristics. The manual provides diagnostic procedures for these and other potential problems.
Oil Filter Part Number Example:
Yamaha 5TA-13440-00-00 or equivalent (e.g., K&N KN-145, HiFloFiltro HF145)
Spark Plug Part Number Example:
NGK CR8E
Brand Heritage:
Yamaha has a long and storied history in motorcycle manufacturing, particularly in off-road and dual-sport segments with its legendary XT and Ténéré lines. The XT660 builds upon this legacy of reliability and single-cylinder performance.
Model Evolution:
The XT660 platform was introduced in the early 2000s, replacing older XT models and incorporating modern technologies like fuel injection. The R variant focused on dual-sport versatility, while the X variant was adapted for supermoto use with larger front brakes, different suspension tuning, and road-biased tires.
Production Years:
The XT660R and XT660X were produced from 2004 to 2016. This manual covers the initial generation.
