This manual provides comprehensive coverage for the XT660R and XT660X models manufactured between 2004 and 2008. These versatile motorcycles are known for their reliable 660cc single-cylinder engine, featuring electronic fuel injection for efficient performance. The XT660R is designed as a dual-sport machine, capable of handling both on-road and light off-road conditions, while the XT660X offers a motard-styled configuration for spirited street riding. Engineering heritage is evident in the robust construction and dependable performance characteristic of the XT lineage, making these models a popular choice for riders seeking adventure and everyday usability. The purpose of this workshop service manual is to serve as an indispensable resource for owners, mechanics, and technicians. It details a wide array of procedures, including routine maintenance, in-depth repair and overhaul instructions for all mechanical and electrical systems, and essential troubleshooting guides. This manual covers everything from basic service intervals and fluid changes to complex engine rebuilds, suspension servicing, and electrical diagnostics. It includes critical technical specifications, torque values, wiring diagrams, and lists of special tools, ensuring that maintenance and repair tasks are performed correctly and efficiently to preserve the longevity and performance of your XT660R or XT660X. 🏷️ Basic Information Identification Make: Yamaha Model: XT660R, XT660X Model Years Covered: 2004, 2005, 2006, 2007, 2008 Codes Chassis Codes: XT660R (often identified by specific VIN prefixes, not explicitly stated in product info), XT660X (often identified by specific VIN prefixes, not explicitly stated in product info) 👋 Introduction Market Position Segment: Dual-sport / Supermoto (XT660R is dual-sport, XT660X is motard-styled) Target Audience: Owners and mechanics seeking detailed information for maintenance, repair, and diagnostics of Yamaha XT660R and XT660X motorcycles. Competitive Analysis Competitors: Competes with other dual-sport and supermoto motorcycles from manufacturers like Honda (e.g., XR series), Kawasaki (e.g., KLR series), Suzuki (e.g., DR-Z series), and KTM (e.g., EXC series) in its displacement class. Key Features Vehicle Focus: Versatile performance for both on-road and light off-road (XT660R) or aggressive street riding (XT660X) with reliable single-cylinder engine technology. 📋 Manual Details Coverage Areas Scope: Comprehensive workshop and repair coverage for Yamaha XT660R and XT660X models Page Count Estimated Pages: Varies by specific manual, typically 300-500 pages for comprehensive workshop manuals Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (presumed, standard for this type of product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Mechanical Systems: Engine (internal components, tuning, diagnostics), Fuel System (injection, pumps, injectors), Ignition System, Cooling System, Lubrication System, Clutch, Transmission, Drive Train (chain, sprockets), Suspension (front forks, rear shock), Brakes (front and rear discs, calipers, master cylinders), Steering, Frame, Wheels, Tires Electrical Systems: Wiring Diagrams, Battery, Charging System (alternator, regulator/rectifier), Starting System (starter motor), Lighting (headlight, taillight, turn signals), Instrumentation, ECU (Engine Control Unit), EFI (Electronic Fuel Injection) System components, Sensors Chassis Components: Frame inspection and repair guidelines, swingarm, linkage (if applicable), footpegs, handlebars, and body panels. Procedures Included Maintenance: Routine service intervals, oil changes, filter replacements, spark plug replacement, chain adjustment and lubrication, brake fluid changes, coolant flushes, valve clearance checks and adjustments Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, error code interpretations (if applicable to EFI system) Repair Overhaul: Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly. Includes engine rebuild procedures, transmission overhaul, suspension fork service, brake caliper servicing, and body panel removal/installation. Electrical Diagnostics: Troubleshooting of electrical faults, testing of sensors, starter motor, charging system components, and lighting circuits using multimeter readings and wiring diagrams. Wheel Tire Service: Information on tire inspection, replacement, wheel balancing, and spoke tensioning (for spoked wheels). Technical Depth Depth: Comprehensive. Covers from basic maintenance tasks to complete engine and component overhauls, advanced diagnostics, and electrical system troubleshooting. Suitable for both experienced DIY mechanics and professional technicians. Torque Specifications: Detailed torque specifications for all critical fasteners throughout the motorcycle, essential for proper assembly and preventing damage. Special Tools: Lists of Yamaha-specific or recommended special tools required for certain maintenance and repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (typically for professionally produced PDFs) Print Quality Printability: Printable pages for workshop use Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, liquid-cooled, SOHC, single-cylinder Displacement: 660 cc Bore X Stroke: 100.0 mm x 84.0 mm Compression Ratio: 10.0:1 Performance Horsepower: Approx. 47 hp (35 kW) @ 6000 rpm (specific figures may vary slightly by market and tuning) Torque: Approx. 60 Nm (44.3 lb-ft) @ 5250 rpm (specific figures may vary slightly by market and tuning) Fuel System Induction: Electronic Fuel Injection (EFI) with dual throttle valves (likely Yamaha's YCC-T or similar system) Fuel Type: Unleaded gasoline Lubrication System Type: Wet sump Ignition Type: TCI (Transistor Controlled Ignition) or CDI (Capacitor Discharge Ignition) with electronic timing advance. 🔧 Transmission Standard Type: Constant mesh...