Yamaha XT660R(S) & XT660X(S) Motorcycle Service Manual - Comprehensive Maintenance & Repair Guide (2004)
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Sample pages from the Yamaha XT660R(S) & XT660X(S) Motorcycle Service Manual - Comprehensive Maintenance & Repair Guide (2004) manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 23349 / Amanda Reyes
- File Size:
- 14.10 MB
- File Type:
- Language:
- English (some of our manuals are multilanguage)
- Pages:
- 462
- Printable:
- Yes
- Estimated Download Time:
- 0.29 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Motorcycle
- Brand:
- Yamaha
- Reviewed and Approved:
- Dec 25, 2025
Yamaha Models and Parts Covered in this Motorcycle Manual
- XT660R (2004)
- XT660X (2004)
- XT660RS (2004)
- XT660XS (2004)
- 5VK1 (2004)
- 5VK2 (2004)
- 5VK3 (2004)
- 1D21 (2004)
- 1D22 (2004)
- 1D23 (2004)
Complete Manual Information
Yamaha XT660R(S) & XT660X(S) Motorcycle Service Manual (2004)
Maximize the performance and longevity of your Yamaha dual-sport or supermoto with this definitive 2004 Service Manual. Covering the legendary XT660 series, this manual is the exact technical resource used by Yamaha dealers and professional mechanics. Whether you are hitting the trails on the XT660R or carving corners on the XT660X, this guide provides the precision data required for every bolt and sensor on your machine.
Supported Models & Series:
This manual is specifically authored for the 2004 model year, covering the following model codes and series designations found in the documentation:
- XT660R (2004) - Dual Purpose Model
- XT660X (2004) - Supermoto Model
- XT660RS / XT660XS - Specific Series Variations
- Series Codes: 5VK1 (Europe), 5VK2 (Australia), 5VK3 (Great Britain)
- Series Codes: 1D21 (Europe), 1D22 (Australia), 1D23 (Great Britain)
Professional Technical Specifications:
The manual contains comprehensive data for the liquid-cooled, 4-stroke, SOHC single-cylinder engine, including:
- Engine ID Mark: 5VK1 00
- Model Specifics: Detailed differences between the R (21-inch front wheel) and X (17-inch front wheel) chassis.
- Precision Clearances: Valve clearance (Cold) specs of 0.09~0.13mm (Intake) and 0.16~0.20mm (Exhaust).
- Torque Master List: From the critical 120 Nm for the drive sprocket nut to the 130 Nm required for the steering stem nut.
Why This Manual is Essential:
Unlike generic repair books, this manual dives deep into the high-tech features of the 2004 XT660, such as the electronically controlled Fuel Injection (FI) system and the sophisticated Immobilizer Anti-Theft system.
Key Maintenance Sections:
- Fuel Injection (FI) System: Full diagnostics for the 44EHS Mikuni throttle body, fuel pump pressure tests (324 kPa), and sensor troubleshooting (TPS, Intake Air Pressure, and Coolant Temp).
- Chassis & Suspension: Complete teardown of the 43mm telescopic forks and the Monocross rear suspension. Includes specific oil levels for both models (640cc for the R, 600cc for the X).
- Electrical & Diagnostics: Wiring diagrams, fuse box layouts (Main 30A), and step-by-step guides for the digital meter assembly and self-diagnosis fault codes.
- Engine Overhaul: Detailed instructions for the dry-sump lubrication system, piston ring installation, and crankshaft assembly using specialized Yamaha tools.
Product Details:
- Format: Comprehensive Service Reference
- Engine Displacement: 660 cm³
- System Focus: Fuel Injection, Electrical, Engine, Chassis, and Cooling Systems
- Safety First: Includes all Safety Alert Symbols and critical warning instructions to ensure vehicle safety and fitness for use.
Stop guessing and start fixing with the correct technical data. This manual ensures that your 5VK series Yamaha remains in peak operating condition, whether you are performing a simple oil change (2.60L with filter) or a complete engine rebuild.
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Frequently Asked Questions - Yamaha Motorcycle Manual
Is this manual suitable for beginners?
Yes, this Yamaha manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Motorcycle maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (14.10 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Yamaha Motorcycle manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Are engine specifications included?
This motorcycle service manual includes detailed engine specifications, valve clearances, torque settings, and performance data specific to your Yamaha model.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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