🏷️ Basic Information

Make:

Yamaha

Model:

XT660

Year:

2004

Chassis Code:

Varies by specific sub-model (e.g., XT660R, XT660X)

Engine Code Prefix:

3DS

👋 Introduction

Market Segment:

Dual-sport / Supermoto motorcycle, known for versatility on and off-road (depending on sub-model).

Competitors 2004:

Suzuki DR-Z400, Honda XR650L, KTM 640 Adventure/LC4.

Engine Type:

Liquid-cooled, four-stroke, SOHC, single-cylinder.

Fuel Delivery:

Electronic Fuel Injection (EFI).

Suspension:

Long-travel, adjustable front forks and rear monoshock absorber for off-road capability.

Variants:

Typically available in XT660R (dual-sport) and XT660X (supermoto) configurations.

📋 Manual Details

General Coverage:

Comprehensive service and repair information for the Yamaha XT660 2004 model.

Estimated Page Count:

~300-400 pages (estimated based on typical factory service manuals for this class of motorcycle)

Type:

Factory Service Repair Manual

Language:

English (typically, though other regional versions exist)

Format:

Digital (PDF) or Printed

📖 Manual Coverage

Engine System:

Complete engine disassembly, assembly, inspection, and repair procedures for the 660cc single-cylinder engine.

Fuel System:

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

Ignition System:

CDI unit, spark plug, ignition coil, timing, and troubleshooting.

Cooling System:

Radiator, fan, coolant flow, thermostat, and maintenance.

Transmission System:

Clutch operation, gear shifting mechanism, gearbox disassembly and assembly, lubrication, and maintenance.

Chassis System:

Frame inspection, front forks (suspension), rear shock absorber, swingarm, linkage, and bearings.

Braking System:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, discs, pads, bleeding procedures, and maintenance.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starter motor, indicators, and ECU.

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable), and component removal/installation.

Wheels And Tires:

Wheel bearings, tire pressure, rim specifications, and spoke tensioning (if applicable).

Bodywork And Trim:

Fairings, seat, fuel tank, fenders, and other cosmetic components.

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication points, spark plug checks, and valve clearance checks.

Troubleshooting:

Diagnostic charts and symptom-based troubleshooting guides for common mechanical and electrical issues.

Engine Repair:

Detailed instructions for engine rebuilds, piston replacement, cylinder head service, and crankshaft inspection.

Transmission Repair:

Gearbox overhaul, shift drum and fork replacement, and clutch pack replacement.

Suspension Service:

Front fork seal replacement, oil changes, rear shock absorber service, and linkage bearing maintenance.

Brake System Overhaul:

Complete brake caliper rebuilding, master cylinder service, and brake line replacement.

Electrical Diagnostics:

Fault finding for starting issues, charging system problems, and sensor failures using wiring diagrams.

Fuel Injection Calibration:

Basic adjustments or diagnostic steps for the EFI system (may require specialized tools/software for advanced tuning).

Depth:

Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and component rebuilds.

📊 Manual Specifications

Digital Format:

PDF (typically searchable and printable)

Print Quality Digital:

High-resolution scans or original digital files ensuring clarity of diagrams and text.

Binding:

N/A (for digital format) / Typically spiral-bound or perfect-bound for printed versions.

Paper Type:

N/A (for digital format) / High-quality, durable paper for printed versions, often with glossy pages for diagrams.

⚙️ Engine Specifications

Displacement:

660cc (659.7cc)

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC, 4 valves per cylinder.

Horsepower Estimate:

Approx. 47.5 hp @ 6,000 rpm (claimed)

Torque Estimate:

Approx. 60 Nm @ 5,250 rpm (claimed)

Fuel Injection:

Mikuni DFI, 44mm throttle body.

Fuel Type:

Unleaded gasoline (95 RON or higher recommended)

Oil Capacity With Filter Change:

Approx. 2.4 liters

Recommended Oil Type:

Yamalube 4-FS 10W-40 or equivalent API SG or higher, JASO MA certified

🔧 Transmission

Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Gear Ratios:

Specific ratios detailed in manual (e.g., 1st: 2.833, 2nd: 1.750, 3rd: 1.333, 4th: 1.095, 5th: 0.917)

📐 Dimensions

Overall Length:

Varies by sub-model (e.g., XT660R ~2,150 mm)

Overall Width:

Varies by sub-model (e.g., XT660R ~850 mm)

Overall Height:

Varies by sub-model (e.g., XT660R ~1,230 mm)

Dry Weight:

Approx. 160-165 kg (depending on sub-model)

Wet Weight:

Approx. 179 kg (depending on sub-model)

Fuel Tank Capacity:

Approx. 15 liters

🛡️ Safety Features

Safety Certification:

CE (European Conformity), EPA (US Environmental Protection Agency) emissions compliance where applicable.

Braking System:

Hydraulic disc brakes front and rear.

Lighting:

Halogen headlight, LED taillight (common), turn signals.

Frame Construction:

Steel diamond frame for rigidity and durability.

💡 Technology Features

Instrument Cluster:

Digital LCD instrument cluster with speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and various indicator lights.

ABS:

Optional ABS available on some models/markets, not standard on all 2004 variants.

ECU Diagnostics:

OBD-II port or diagnostic connectors for ECU fault code reading (may require specific Yamaha diagnostic tool).

🔧 Maintenance

Oil Change Interval:

Every 5,000 km or 6 months, whichever comes first.

Air Filter Cleaning:

Every 5,000 km or 6 months, replace if necessary.

Spark Plug Replacement:

Every 10,000 km or 12 months.

Valve Clearance Check:

Every 20,000 km or 24 months.

Chain Lubrication Adjustment:

Every 1,000 km or after washing/riding in rain.

Brake Fluid:

DOT 4

Coolant Type:

Yamaha Power Coolant or equivalent (50/50 mix of ethylene glycol and distilled water)

Common Problems:

Potential for stator failure, clutch slave cylinder leaks, and occasional EFI sensor issues. These are detailed troubleshooting steps for these in the manual.

📚 Vehicle History

Yamaha Legacy:

Yamaha's long-standing reputation for building reliable and performance-oriented motorcycles, particularly in the off-road and dual-sport segments.

Xt Lineage:

The XT660 builds upon Yamaha's legendary XT series, known for its ruggedness and off-road prowess.

Production Period:

The XT660 platform was produced from the early 2000s through the 2010s, with various updates and sub-models.

🏆 Awards & Recognition

Awards Or Recognition:

Generally well-regarded for its torque and versatility in the dual-sport/supermoto categories. Specific awards for the 2004 model are not widely publicized but it has a strong following among enthusiasts.