🏷️ Basic Information

Make:

Yamaha

Model:

XT660R / XT660X

Model Variants:

XT660R (Dual-sport/Enduro), XT660X (Supermoto)

Chassis Codes:

Likely varying by market, common internal designations exist

Engine Codes:

Commonly associated with the 3YF engine family (specific internal codes may vary)

👋 Introduction

Segment:

Lightweight dual-sport (XT660R) and Supermoto (XT660X) motorcycles.

Target Audience:

Owners, mechanics, and enthusiasts seeking in-depth knowledge for maintenance, repair, and customization of the XT660R/X.

Competitors:

Competed against other single-cylinder dual-sport and supermoto offerings from manufacturers like KTM, Honda, and Suzuki in its era.

Engine Character:

Torquey 660cc single-cylinder engine, known for its usable power across a broad RPM range.

Versatility:

The XT660R is a capable all-rounder for commuting and light off-road riding, while the XT660X excels in urban agility and spirited riding.

Value Proposition:

Provides factory-level technical data and procedures, enabling confident DIY maintenance and repairs, potentially saving significant costs.

📋 Manual Details

Years Covered:

2004, 2005, 2006, 2007, 2008, 2009

Models Covered:

Yamaha XT660R, Yamaha XT660X

Page Count:

462

Manual Type:

Factory Service Manual (FSM)

Language:

English (ENG)

File Format:

PDF

Print Quality:

High Quality

Features:

Fully Printable, Bookmarked

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, tuning, and diagnostics for the 660cc single-cylinder liquid-cooled engine.

Fuel System:

Fuel injection system (EFI) components, sensors, ECU, fuel pump, injectors, and troubleshooting.

Cooling System:

Radiator, coolant, water pump, thermostat, and fan operation.

Transmission:

Gearbox operation, clutch service, shifting mechanisms, and lubrication.

Electrical System:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), ignition system, lighting, starter motor, and electronic control unit (ECU).

Chassis Suspension:

Front forks (including oil changes, seal replacement, and damping adjustments), rear shock absorber (linkage and spring preload adjustments), swingarm, and bearings.

Brakes:

Front and rear brake systems, including hydraulic lines, master cylinders, calipers, brake pads, rotors, and bleeding procedures.

Wheels Tires:

Wheel bearing service, spoke tensioning (for XT660R), tire mounting and balancing.

Bodywork:

Fairings, fuel tank, seat, fenders, and associated fasteners.

Controls:

Throttle, clutch lever, brake lever, and shifter mechanism adjustments and service.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain maintenance, brake fluid flushes, and coolant checks.

Disassembly Reassembly:

Step-by-step instructions for complete disassembly and reassembly of all major components and systems.

Troubleshooting:

Diagnostic procedures for common electrical and mechanical faults, including fault code interpretation (if applicable).

Repair:

Detailed repair instructions for worn or damaged parts, including engine rebuilds, suspension overhauls, and electrical system repairs.

Wiring Diagrams:

Comprehensive and detailed wiring diagrams for all electrical systems, facilitating fault finding and component identification.

Depth:

Advanced, covering complete overhauls, complex diagnostics, and detailed technical specifications.

Visuals:

Hundreds of high-quality photos illustrating each step of disassembly and reassembly procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable due to PDF format, enhancing usability.

Printability:

Fully printable, allowing users to create physical copies for workshop use.

Binding Type:

Not applicable for PDF, but if printed, typically spiral-bound or comb-bound for lay-flat use.

Paper Quality:

Not applicable for PDF, but professional printing would utilize durable, high-quality paper.

Bookmarking:

Yes, enhances navigation through the extensive content.

⚙️ Engine Specifications

Type:

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

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1 (typical, may vary slightly by market)

Horsepower:

Approximately 47-48 hp @ 6000 rpm (claimed, may vary)

Torque:

Approximately 60-62 Nm @ 5250 rpm (claimed, may vary)

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves (likely YCC-T derived systems).

Fuel Type:

Unleaded gasoline (Octane rating specified in manual)

Oil Type:

Yamaha recommends specific JASO MA certified 4-stroke motorcycle oils (e.g., Yamalube 10W-40 or equivalent).

Ignition System:

TCI (Transistor Controlled Ignition) or CDI (Capacitor Discharge Ignition) with electronic advance.

Crankshaft:

Forged or cast, specific details in manual.

Pistons:

Single piston ring design typical for this displacement.

Valvetrain:

DOHC (Double Overhead Camshaft) is incorrect for this model. It is SOHC (Single Overhead Camshaft) with 4 valves.

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multiple-disc, cable-actuated

Gear Ratios:

Specific gear ratios for each of the 5 speeds and final drive are detailed in the manual.

Final Drive:

Chain drive (O-ring sealed)

Transmission Oil Type:

Yamaha recommends API SG or higher, SAE 10W-30 for the engine oil which also lubricates the transmission and clutch.

📐 Dimensions

Length Xt660R:

Approx. 2,235 mm (88.0 in)

Length Xt660X:

Approx. 2,175 mm (85.6 in)

Width Xt660R:

Approx. 845 mm (33.3 in)

Width Xt660X:

Approx. 830 mm (32.7 in)

Height Xt660R:

Approx. 1,205 mm (47.4 in)

Height Xt660X:

Approx. 1,120 mm (44.1 in)

Dry Weight Xt660R:

Approx. 170 kg (375 lbs)

Dry Weight Xt660X:

Approx. 170 kg (375 lbs)

Wet Weight Xt660R:

Approx. 182 kg (401 lbs) (with all fluids and full tank)

Wet Weight Xt660X:

Approx. 182 kg (401 lbs) (with all fluids and full tank)

Fuel Capacity:

15 Liters (4.0 US gal)

Seat Height Xt660R:

Approx. 860 mm (33.9 in)

Seat Height Xt660X:

Approx. 855 mm (33.7 in)

Ground Clearance Xt660R:

Approx. 210 mm (8.3 in)

Ground Clearance Xt660X:

Approx. 135 mm (5.3 in)

Front Tire Xt660R:

90/90-21 M/C 54S (Tube type)

Rear Tire Xt660R:

130/80-17 M/C 65S (Tube type)

Front Tire Xt660X:

110/70-17 M/C 54H (Tubeless)

Rear Tire Xt660X:

160/60-17 M/C 69H (Tubeless)

Front Wheel Xt660R:

Spoked, 21-inch

Rear Wheel Xt660R:

Spoked, 17-inch

Front Wheel Xt660X:

Cast alloy, 17-inch

Rear Wheel Xt660X:

Cast alloy, 17-inch

🛡️ Safety Features

Safety Features Standard:

Comprehensive lighting system, audible horn, reflective elements.

ABS:

ABS was not a standard or widely available option for these models during the specified production years.

Braking System:

Hydraulic disc brakes front and rear, providing effective stopping power.

Chassis Design:

Robust frame design contributing to stability and rider control.

Ergonomics:

Designed for comfortable rider positioning, aiding control during various riding conditions.

💡 Technology Features

Dashboard:

Digital LCD instrument cluster displaying speed, RPM, fuel level, odometer, trip meters, and indicator lights.

Traction Control:

Traction control systems were not typically offered on these models.

Usb Charging:

No built-in USB charging ports; aftermarket solutions are available.

ECU:

Electronic Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. Advanced diagnostics possible with appropriate tools, detailed in the manual.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first. Refer to manual for specific conditions.

Oil Filter Replacement:

At every oil change.

Air Filter Cleaning:

Recommended every 5,000 km (3,000 miles) or more frequently in dusty conditions.

Spark Plug Replacement:

Typically around 20,000 km (12,000 miles), dependent on plug type and usage. Manual will specify exact interval and plug type (e.g., NGK CR9E).

Chain Lubrication Adjustment:

Lubrication: Every 500-1000 km. Adjustment: As needed, typically when slack exceeds specified limit (e.g., 20-30 mm).

Brake Fluid Flush:

Recommended every 2 years or as per manual specifications to maintain system performance.

Coolant Replacement:

Typically every 2-3 years or as specified in the manual.

Engine Oil Capacity:

Approx. 2.4 Liters (2.5 US qt) without filter change, 2.7 Liters (2.8 US qt) with filter change. Precise capacity in manual.

Coolant Type:

Yamaha recommends a high-quality ethylene glycol based coolant for radiators, mixed with distilled water (typically 50/50 ratio). Specific part number in manual.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Common Wear Items:

Clutch plates (especially with aggressive riding), wheel bearings, and fork seals can be common wear items over time.

Efi Issues:

While generally reliable, occasional issues with sensors (e.g., TPS, MAP) or fuel pump can occur. The manual's diagnostic section is crucial.

Suspension Performance:

Some riders find the stock suspension can be a bit soft for aggressive riding; the manual provides guidance for adjustments and upgrades.

Engine Bolt Torques:

Critical torque values for cylinder head, crankcase, and other engine components are provided in detail within the manual.

Chassis Bolt Torques:

Torque specifications for wheel axles, swingarm pivots, and suspension mounting points are essential for safety and will be found in the manual.

📚 Vehicle History

Heritage:

Yamaha has a long and storied history in off-road and dual-sport motorcycles, dating back to the iconic XT500 and its successors.

Predecessors:

The XT660 series built upon the legacy of previous XT models, incorporating modern technology like fuel injection.

Xt660 Introduction:

The XT660R and XT660X were introduced to cater to riders seeking a more powerful and modern single-cylinder adventure/supermoto experience.

Manufacturing Location:

Primarily manufactured in Japan, though specific assembly locations may vary by market.

Production Run:

The XT660R/X platform had a considerable production run, with updates and refinements over the years, but this manual specifically covers the 2004-2009 period.

🏆 Awards & Recognition

Awards:

Specific awards for the XT660R/X models are not prominently documented, but the platform has been recognized for its versatility and reliable single-cylinder performance in the dual-sport and supermoto categories by automotive publications and rider reviews.

Rider Reviews:

Generally well-regarded for its torquey engine, comfortable riding position (XT660R), and agile handling (XT660X), often praised for its simplicity and capability as a workhorse.