Yamaha Xt-660 2007 Factory Service Manual Repair

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🏷️ Basic Information Identification Make: Yamaha Model: XT660 Year: 2007 👋 Introduction Market Position Motorcycle Segment: Dual-sport / Adventure-touring motorcycle. Target Audience: Riders seeking versatility for on-road commuting and off-road...

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类型: Motorcycle

斯库: 485341

标签: 2007 Motorcycle Motorcycles XT Models Xt-660 Yamaha

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT660

Year:

👋 Introduction

Market Position

Motorcycle Segment:

Dual-sport / Adventure-touring motorcycle.

Target Audience:

Riders seeking versatility for on-road commuting and off-road exploration.

Competitive Analysis

Key Competitors 2007:

KTM 690 Enduro, Honda XR650L, Kawasaki KLR650, Suzuki DR650SE.

Key Features

Engine Type:

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

Fuel Delivery:

Electronic Fuel Injection (EFI) for precise fueling and emissions control.

Chassis Design:

Robust steel frame designed for durability and off-road capability.

Suspension Setup:

Long-travel telescopic front forks and adjustable rear monoshock for varied terrain.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, inspection, and adjustment of all engine components.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines, and EVAP system.

Cooling System:

Radiator, fan, water pump, coolant hoses, thermostat, and system pressure testing.

Exhaust System:

Exhaust pipes, muffler, catalytic converter, and lambda sensor (oxygen sensor) replacement and inspection.

Transmission Drivetrain:

Clutch operation, gearbox inspection and repair, final drive (chain and sprockets), and oil change procedures.

Electrical System:

Ignition system, starting system, charging system (alternator, regulator/rectifier), lighting, battery, wiring diagrams, and ECU diagnostics.

Suspension System:

Front forks (telescopic, cartridge type), rear shock absorber, linkage, and adjustment procedures.

Braking System:

Front and rear disc brakes, hydraulic system, brake pads, calipers, master cylinders, and bleeding procedures.

Wheel And Tire System:

Wheel bearing inspection and replacement, tire pressure, rim specifications, and spoke tension (if applicable).

Steering System:

Handlebars, steering stem bearings, and lubrication.

Chassis Frame:

Frame inspection, component mounting, and general chassis structure.

Bodywork Fairings:

Removal, installation, and repair of body panels, seats, and accessories.

Procedures Included

General Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, fluid level checks, and general inspections.

Troubleshooting:

Diagnostic procedures for common issues, error code interpretation, and symptom-based troubleshooting guides.

Engine Rebuilding:

Detailed step-by-step instructions for complete engine disassembly, component measurement, and reassembly.

Electrical Diagnostics:

Wiring diagrams, component testing, and fault finding for all electrical systems.

Suspension Adjustment:

Setting up front and rear suspension for optimal performance and rider preference.

Brake System Service:

Brake pad replacement, caliper service, master cylinder overhaul, and brake fluid bleeding.

Efi Tuning:

Diagnosis and potential minor adjustments related to the electronic fuel injection system.

Technical Depth

Depth:

Comprehensive, covering everything from basic rider maintenance to complete engine and chassis overhauls. Includes diagnostic procedures, specifications, and torque values for all components.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text content for easy navigation and information retrieval.

Print Quality:

High-resolution scans suitable for printing.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Page Count

Estimated Page Count:

Approximately 300-400 pages (typical for this model and type of manual).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, SOHC, 4-valve, single-cylinder

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

9.2:1

Fuel System:

Mikuni DFI (Digital Fuel Injection) with throttle position sensor (TPS) and idle air control valve (IACV).

Ignition System:

TCI (Transistor Controlled Ignition)

Performance

Claimed Horsepower:

Approximately 47 hp @ 6000 rpm (varies by market and tuning)

Claimed Torque:

Approximately 60 Nm (44.3 lb-ft) @ 5250 rpm (varies by market and tuning)

Fuel System

Throttle Body Diameter:

48 mm

Fuel Type:

Unleaded gasoline (91 RON or higher recommended)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 5-speed

Clutch Type:

Wet, multi-plate, manual

Features

Final Drive:

O-ring sealed chain, 15/45T sprockets (typical).

📐 Dimensions

Exterior

Length:

2,250 mm (approx. 88.6 in)

Width:

860 mm (approx. 33.9 in)

Height:

1,475 mm (approx. 58.1 in) (seat height varies)

Wheelbase:

1,475 mm (approx. 58.1 in)

Ground Clearance:

260 mm (approx. 10.2 in)

Weights

Dry Weight:

Approx. 162 kg (357 lbs) (specifications vary)

Wet Weight:

Approx. 175 kg (386 lbs) (with fluids, varies)

Fuel Tank Capacity:

15 Liters (3.96 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

Meets relevant European and international safety standards for motorcycles.

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Passive Features

Frame Construction:

Robust steel frame designed to absorb impacts and provide stability.

Lighting:

Halogen headlamp for good nighttime visibility.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital multi-function instrument cluster displaying speed, RPM, fuel level, odometer, trip meters, and warning lights.

Driver Assistance

ABS was an optional feature on some markets for the XT660 models.

Connectivity

Diagnostic Ports:

On-board diagnostics (OBD) port for electronic fault code retrieval by technicians.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 5,000 km (3,000 miles) or annually.

Spark Plug Check Replace:

Check at 10,000 km (6,000 miles), replace as needed.

Air Filter Cleaning Replace:

Clean every 5,000 km (3,000 miles), replace as needed (more frequently in dusty conditions).

Chain Lubrication Adjustment:

Lubricate every 1,000 km (600 miles) or after riding in rain; adjust chain slack every 5,000 km (3,000 miles).

Fluid Specifications

Engine Oil:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified.

Engine Oil Capacity:

2.1 Liters (with filter change), 1.9 Liters (without filter change).

Coolant:

High-quality ethylene glycol-based coolant, 50% mixture with distilled water.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Transmission Oil:

Same as engine oil: Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified.

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, fork seals, and regulator/rectifier (in some cases).

Potential Engine Quirks:

Some units may experience mild vibration at certain RPMs; ensuring proper maintenance is key to longevity.

Efi System Maintenance:

Regular cleaning of the throttle body and checking for vacuum leaks are recommended for optimal EFI performance.

📚 Vehicle History

Brand Heritage

Brand Focus:

Yamaha Corporation, a Japanese multinational corporation, is renowned for its wide range of products, including motorcycles, musical instruments, and audio equipment.

Model Evolution

Xt Series Lineage:

The XT series has a long history dating back to the early XT500, a pioneering dual-sport motorcycle. The XT660 builds on this legacy with modern technology and performance enhancements.

Production

Original Production Start:

The XT660 platform was introduced in the early 2000s, with various iterations and updates over the years.

2007 Model Variants:

The 2007 model was available in several variants, including the XT660R (supermoto-styled) and XT660X (dual-sport/enduro).

🏆 Awards & Recognition

Recognitions

Market Reception:

The XT660 series has been generally well-received by riders for its robust build, versatile performance, and capable single-cylinder engine, particularly in the dual-sport and adventure touring segments.