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2007 Yamaha Xt-660 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: XT660 Year: 2007 Segment: Dual-sport / Adventure motorcycle Variants XT660R: Spoked wheels, more off-road oriented XT660X: Alloy wheels, Supermoto style XT660Z Ténéré: Larger...
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Tür: Motorcycle
Satıcı:
SKU: 493926
Etiketler:
2007
Motorcycle
Motorcycles
XT Models
Xt-660
Yamaha
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XT660
Year:
2007
Segment:
Dual-sport / Adventure motorcycle
Variants
XT660R:
Spoked wheels, more off-road oriented
XT660X:
Alloy wheels, Supermoto style
XT660Z Ténéré:
Larger fuel tank, wind protection, adventure focus
Model Code:
XT660R/X/Z (specific variants may have internal Yamaha codes)
👋 Introduction
Market Position
Segment:
Dual-sport/Adventure motorcycle
Target Audience:
Riders seeking a versatile motorcycle for on-road commuting and off-road exploration
Competitive Analysis
Competitors:
BMW F650GS, Honda Transalp, Kawasaki KLR650, Suzuki V-Strom 650
Key Features
Engine Type:
Liquid-cooled, SOHC, 4-valve, single-cylinder
Fueling:
Electronic fuel injection (EFI)
Suspension:
Long-travel telescopic front forks, Monocross rear suspension
Variants:
XT660R, XT660X, XT660Z Ténéré
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Vehicle Covered:
2007 Yamaha XT660 (R/X/Z variants)
Format & Delivery
File Format:
PDF
Delivery Method:
Instant digital download
Binding:
Digital (no physical binding)
Page Count
Estimated Page Count:
400-600 pages (typical for comprehensive motorcycle factory service manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine teardown, assembly, cylinder head, valve train, pistons, crankshaft, lubrication system, cooling system
Fuel System:
Fuel injection system, throttle body, fuel pump, injectors, fuel pressure regulator, evaporative emission control system
Ignition System:
Ignition control unit (ECU), ignition coils, spark plugs, wiring diagrams
Transmission:
Clutch operation and service, gearbox components, shift mechanism, lubrication
Chassis Frame:
Frame inspection, steering head bearings, suspension component removal/installation
Front Suspension:
Front fork disassembly, assembly, oil change, seal replacement, damping adjustments
Rear Suspension:
Rear shock absorber service, linkage maintenance, swingarm removal/installation
Braking System:
Brake fluid change, caliper service, master cylinder overhaul, pad replacement, disc inspection
Wheels & Tires:
Wheel bearing service, tire replacement, spoke tensioning (if applicable to variants)
Electrical System:
Battery service, charging system (stator, regulator/rectifier), starter motor, lighting, horn, instrumentation
Wiring Diagrams:
Complete electrical schematics for all systems
Bodywork & Trim:
Fairing removal/installation, seat, fuel tank, fenders, graphics
Procedures Included
Routine Maintenance:
Oil change, filter replacement, chain adjustment, spark plug replacement, air filter service, brake bleeding
Troubleshooting:
Diagnostic charts and procedures for common problems
Major Repairs:
Engine rebuild, transmission overhaul, suspension refurbishment
Disassembly & Assembly:
Step-by-step instructions for virtually all components
Technical Depth
Diagnostic Procedures:
Detailed procedures for identifying and resolving issues, including electronic diagnostics
Specifications & Tolerances:
Precise torque values, clearances, measurements, and tolerances for all parts
Special Tools:
Identification of Yamaha-specific tools required for certain procedures
Parts Information:
Part numbers and specifications referenced throughout service procedures
📊 Manual Specifications
File & Compatibility
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print & Binding
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
⚙️ Engine Specifications
Primary Engine
Engine Code:
10Y (or similar Yamaha internal code)
Configuration:
Single-cylinder, 4-stroke
Displacement:
660 cc
Bore x Stroke:
100 mm x 84 mm
Compression Ratio:
10.0:1
Valve Train:
SOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 47.3 HP @ 6000 RPM
Torque:
Approx. 60 Nm (44.3 lb-ft) @ 5250 RPM
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Mikuni throttle body
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication:
Yamalube 4 (or equivalent) SAE 10W-40, API SG or higher
Oil Capacity:
Approx. 2.4 L (2.5 US qt) with oil filter change
🔧 Transmission
Standard Transmission
Type:
5-speed constant mesh
Clutch:
Wet, multi-plate, cable-actuated
Features
Final Drive:
O-ring sealed chain drive
Optional Transmission:
N/A - 5-speed constant mesh was the only gearbox fitted across the XT660 range
📐 Dimensions
Exterior
Overall Length:
Varies by variant (XT660R approx. 2125 mm)
Overall Width:
Varies by variant (XT660R approx. 830 mm)
Overall Height:
Varies by variant (XT660R approx. 1180 mm)
Wheelbase:
Varies by variant (XT660R approx. 1455 mm)
Ground Clearance:
Varies by variant (XT660R approx. 210 mm)
Weights
Dry Weight:
Varies by variant (XT660R approx. 165 kg / 364 lbs)
Wet Weight:
Approx. 174 kg / 384 lbs (XT660R, with fluids)
Fuel Capacity:
Approx. 15 L (3.96 US gal) XT660R/X; 20 L (5.3 US gal) XT660Z Ténéré
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable to motorcycles in the same way as cars; design complies with applicable safety regulations
Active Features
Brakes:
Hydraulic disc brakes front and rear; ABS available on some variants/markets
Lighting:
Halogen headlight, LED taillight/brake light, incandescent or LED turn signals
Passive Features
Frame Construction:
Steel diamond frame for rigidity and impact absorption
Ergonomics:
Designed for rider control and comfort during varied riding conditions
💡 Technology Features
Infotainment
Instrumentation:
Digital LCD instrument cluster with speedometer, tachometer, fuel gauge, odometer, trip meters, clock, and indicator lights
Driver Assistance
ABS Availability:
Available on certain model years and markets as an option
ECU Diagnosis:
Diagnostic connectors for EFI tuning and fault diagnosis
🔧 Maintenance
Service Intervals
Oil & Filter Change:
Every 6,000 km (3,700 mi) or 6 months
Air Filter Inspection:
Every 6,000 km (3,700 mi)
Spark Plug Replacement:
Every 12,000 km (7,500 mi)
Valve Clearance Check:
Every 24,000 km (15,000 mi)
Chain Lubrication & Adjustment:
Every 1,000 km (600 mi) or after riding in rain/dust
Fluid Specifications
Engine Oil:
Yamalube 4 (or equivalent) SAE 10W-40, API SG or higher
Coolant:
Permanent type antifreeze coolant (ethylene glycol-based), 50% solution with distilled water
Brake Fluid:
DOT 4 specification (refer to manual for specific Yamaha part number)
Transmission Oil:
Refer to manual; typically SAE 80 API GL-4 or GL-5 gear oil or equivalent
Known Issues / Common Wear Items
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings
Potential Quirks:
Some owners report vibrations at certain RPMs or slightly abrupt EFI throttle response; regular maintenance is key to longevity
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation
Offroad Legacy:
Long history in off-road and dual-sport motorcycles, stemming from iconic models like the XT500 and Ténéré range
Model Evolution
XT660 Lineage:
Evolved from earlier Yamaha single-cylinder engines, offering a modern, fuel-injected approach to the dual-sport segment
Production
Manufacturing Location:
Primarily manufactured in Japan by Yamaha Motor Corporation
🏆 Awards & Recognition
Recognitions
Model Recognition:
The XT660Z Ténéré name pays homage to Yamaha's Dakar Rally-winning Ténéré models of the 1980s
Market Standing:
Widely regarded as a durable, capable single-cylinder dual-sport platform throughout its production run
Official Awards:
N/A - no specific factory-listed awards documented for the 2007 model year