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Yamaha XT660R(S) XT660X(S) Complete OFFICIAL Factory Service / Repair / Workshop Manual PDF Download
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Basic Information Identification Make: Yamaha Model: XT660R, XT660X Model Variants: XT660R(S), XT660X(S) Codes Chassis Codes: XT660R: 5VK, XT660X: 108000 onwards Introduction Market Position Segment: Dual-sport / Supermoto Target Audience: Owners...
Type: Motorcycles
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Sku: 39006
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| Basic Information | |
| Identification | |
| Make: | Yamaha |
| Model: | XT660R, XT660X |
| Model Variants: | XT660R(S), XT660X(S) |
| Codes | |
| Chassis Codes: | XT660R: 5VK, XT660X: 108000 onwards |
| Introduction | |
| Market Position | |
| Segment: | Dual-sport / Supermoto |
| Target Audience: | Owners and technicians performing maintenance, repair, and customization on Yamaha XT660R and XT660X models. |
| Competitive Analysis | |
| Competitors: | Other single-cylinder dual-sport and supermoto motorcycles from manufacturers like Honda (e.g., XR series), Suzuki (e.g., DR-Z series), Kawasaki (e.g., KLR series), and KTM (e.g., LC4 series). |
| Key Features | |
| Engine Type: | Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder engine. |
| Fuel Delivery: | Electronic Fuel Injection (EFI) for improved performance, fuel efficiency, and emissions control. |
| Chassis Design: | Lightweight frame designed for agility and stability in both on-road and light off-road conditions (XT660R) or optimized for urban and track use (XT660X). |
| Suspension Setup: | Long-travel, adjustable suspension (telescopic front forks, monoshock rear) providing comfort and control. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Complete Factory Service / Repair / Workshop |
| Page Count | |
| Estimated Page Count: | Over 500 pages (typical for comprehensive factory manuals) |
| Manual Type | |
| Type: | Official Factory Service Manual / Workshop Manual |
| Language | |
| Language: | English (typically, but official manuals may have multiple language options) |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Engine disassembly, assembly, tuning, diagnosis, specifications for XT660 engine family. |
| Fuel System: | Fuel injection system (EFI), throttle body, injectors, fuel pump, pressure regulator, fuel tank, lines. |
| Ignition System: | Ignition coil, CDI unit, spark plugs, wiring diagrams. |
| Cooling System: | Radiator, cooling fan, water pump, thermostat, coolant specifications and bleeding procedures. |
| Transmission: | Clutch operation, gear shifting mechanism, transmission gear ratios, lubrication, diagnosis. |
| Chassis And Frame: | Frame construction, swingarm, bearings, suspension linkages, steering head bearings. |
| Suspension: | Front forks (telescopic), rear shock absorber (monoshock), adjustment, rebuild, oil specifications, seals. |
| Brakes: | Front and rear disc brakes, brake calipers, master cylinders, brake lines, brake fluid specifications and bleeding, ABS (if applicable). |
| Electrical System: | Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting, starter motor, fuses, relays, sensors. |
| Instrumentation And Controls: | Dashboard, switches, levers, cables, throttle control, clutch lever. |
| Bodywork And Trim: | Fairings, seat, fuel tank cover, fenders, graphics, disassembly and reassembly. |
| Wheels And Tires: | Wheel removal and installation, spoke tensioning (spoked wheels), tire types, pressures, sizes. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, air filter cleaning/replacement, brake fluid checks. |
| Troubleshooting: | Diagnostic procedures for common and uncommon problems, fault code interpretation (if applicable), electrical system checks, engine performance issues. |
| Major Repairs: | Engine rebuild procedures, transmission overhauls, suspension rebuilds, electrical component replacement. |
| Component Disassembly Reassembly: | Step-by-step instructions for removing, inspecting, repairing, and reinstalling all major components and sub-assemblies. |
| Specifications And Tolerances: | Detailed torque specifications for all fasteners, engine clearances, dimensional tolerances, electrical resistance values. |
| Technical Depth | |
| Depth: | Comprehensive (covers everything from basic maintenance to full engine and chassis rebuilds). |
| Manual Specifications | |
| File Format | |
| Format: | |
| Print Quality | |
| Quality: | High-resolution, searchable text, printable pages (typical for official factory PDFs). |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Liquid-cooled, four-stroke, SOHC, four-valve, single-cylinder |
| Displacement: | 660 cc |
| Bore X Stroke: | 100.0 mm x 84.0 mm |
| Compression Ratio: | 10.0:1 |
| Performance | |
| Max Horsepower: | Approx. 47-48 HP (35 kW) @ 6000 rpm (varies slightly by region and model year) |
| Max Torque: | Approx. 60-61 Nm (44-45 lb-ft) @ 5250 rpm (varies slightly by region and model year) |
| Fuel System | |
| Fuel Induction: | Electronic Fuel Injection (EFI) with twin-injector system (primary and secondary) |
| Throttle Body Diameter: | 48 mm |
| Fuel Type: | Unleaded gasoline (91 RON or higher recommended) |
| Lubrication | |
| Oil Type: | Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher |
| Oil Capacity: | 2.3 L (without filter change), 2.5 L (with filter change) |
| Transmission | |
| Standard | |
| Type: | Constant mesh 5-speed |
| Clutch: | Wet, multiple-disc, cable-actuated |
| Features | |
| Final Drive: | Chain drive |
| Gear Ratios: | 1st: 2.833 (34/12), 2nd: 1.933 (29/15), 3rd: 1.500 (27/18), 4th: 1.250 (25/20), 5th: 1.045 (23/22) |
| Dimensions | |
| Exterior | |
| Length Xt660R: | 2,175 mm (85.6 in) |
| Length Xt660X: | 2,180 mm (85.8 in) |
| Width Xt660R: | 845 mm (33.3 in) |
| Width Xt660X: | 860 mm (33.9 in) |
| Height Xt660R: | 1,230 mm (48.4 in) |
| Height Xt660X: | 1,220 mm (48.0 in) |
| Seat Height Xt660R: | 875 mm (34.4 in) |
| Seat Height Xt660X: | 865 mm (34.1 in) |
| Wheelbase Xt660R: | 1,475 mm (58.1 in) |
| Wheelbase Xt660X: | 1,480 mm (58.3 in) |
| Weights | |
| Dry Weight Xt660R: | 174 kg (384 lbs) |
| Dry Weight Xt660X: | 172 kg (379 lbs) |
| Fuel Tank Capacity: | 15 L (3.96 US gal) |
| Oil Capacity: | 2.3 L (without filter change), 2.5 L (with filter change) |
| Luggage Capacity: | N/A (designed as a single-seater, though aftermarket racks are common) |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | Not applicable to motorcycles in the same way as cars. |
| Active Features | |
| Braking System: | Dual hydraulic disc front brake, single hydraulic disc rear brake. ABS available on some later models (check specific VIN). |
| Lighting: | Halogen headlight, LED taillight, front and rear turn signals. |
| Passive Features | |
| Frame Construction: | Steel diamond frame for rigidity and impact absorption. |
| Ergonomics: | Upright riding position designed for rider control and visibility. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (Motorcycle focuses on essential functions; infotainment is not a feature). |
| Driver Assistance | |
| ABS: | Available on select models/years, enhancing braking safety. |
| Connectivity | |
| Connectivity Features: | N/A (Motorcycle focuses on core performance and control). |
| Engine Management | |
| ECU: | Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters for optimal performance and emissions. |
| Instrumentation | |
| Dashboard: | Digital LCD instrument cluster providing speed, RPM, fuel level, odometer, trip meters, clock, and warning lights. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 5,000 km (3,100 miles) or 6 months, whichever comes first. |
| Oil Filter Change Interval: | Every 10,000 km (6,200 miles) or 12 months, or with every oil change. |
| Air Filter Cleaning: | Every 5,000 km (3,100 miles) or 6 months. Replacement recommended every 20,000 km (12,400 miles). |
| Spark Plug Inspection: | Every 10,000 km (6,200 miles). |
| Chain Lubrication Adjustment: | Every 1,000 km (620 miles) or after riding in wet conditions. Adjust every 15,000 km (9,300 miles). |
| Brake Fluid Replacement: | Every 2 years or 20,000 km (12,400 miles). |
| Fluid Specifications | |
| Engine Oil: | Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher |
| Coolant: | High-quality ethylene glycol-based antifreeze coolant with demineralized water (50/50 mixture). |
| Brake Fluid: | DOT 4 |
| Fork Oil Type Level: | Yamaha Suspension Fluid (or equivalent) 10W, level 120mm (specific to fork configuration, consult manual). |
| Known Issues | |
| Stator Failure: | Some units may experience stator failures causing charging system issues. |
| Fuel Pump Reliability: | Occasional issues with fuel pump performance have been reported. |
| Starter Clutch Wear: | On older or heavily used models, starter clutch wear can lead to starting problems. |
| Exhaust Flange Gasket Leaks: | The exhaust header flange gasket can sometimes fail, leading to exhaust leaks. |
| Vehicle History | |
| Brand Heritage | |
| Yamaha Motorcycles: | Yamaha Motor Corporation is renowned for its innovation, performance, and reliability across a wide range of motorcycles, from sportbikes to off-road and adventure models. The XT lineage is a significant part of Yamaha's history in the dual-sport segment. |
| Model Evolution | |
| Xt660 Lineage: | The XT660 series was developed as a successor to earlier XT models, leveraging modern technology like fuel injection and liquid cooling in a single-cylinder platform. It was designed to offer a blend of off-road capability (XT660R) and street-focused performance (XT660X). |
| Production | |
| Production Years: | Approximately 2004 - 2016 (subject to regional variations). |
| Manufacturing Location: | Primarily manufactured in Japan and/or France. |
| Awards & Recognition | |
| Recognitions | |
| Industry Recognition: | While specific awards are hard to pinpoint without a definitive historical database, the XT660 series has been generally well-regarded in motorcycle publications for its robust single-cylinder engine, versatility, and value for money in the dual-sport and supermoto segments. |
| Ratings | |
| User Reviews: | Generally positive user reviews highlight reliability, torque, and suitability for commuting and light touring, with some users appreciating its off-road capability (XT660R) and urban agility (XT660X). |
| Certifications | |
| Emissions Compliance: | Designed to meet applicable emissions standards for its respective production years and markets (e.g., Euro 3). |