2004 Yamaha XT660R / XT660X Service Manual (462 Pages)
Complete diagnostic reference for XT660 fuel-injection engine and chassis assembly. Covers 660cc displacement, electronic FI system, and 5-speed transmission with detailed repair procedures and wiring schematics.
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Sample pages from the 2004 Yamaha XT660R / XT660X Service Manual (462 Pages) manual
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Models Covered & Key Technical Specifications
Yamaha XT660R(S) & XT660X(S) — 2004 Procedural Technical Digest | XT660 Series Folder.
- Designated Displacement Data: 660 cm³ (40.27 cu·in) is specified as the engine cylinder volume Sequences.
- Primary Idle Speed Rating: For optimal performance, 1,300 ~ 1,500 r/min establishes the standard engine idling speed Baseline.
- Measured Compression Specification: 650 kPa (6.5 kg/cm², 92.4 psi) — indicates the standard compression pressure Requirements.
- Design Fuel Capacity: The fuel tank requires 15.0 L (3.96 US gal) for total storage Threshold.
- Engineered Oil Capacity: Engine oil system corresponds to 2.90 L (3.07 US qt) total capacity Mapping.
- Certified Coolant Volume: Cooling system supports 1.00 L (1.06 US qt) coolant capacity Configuration.
Professional Workshop Service Manual & Technical Specifications
Full-Coverage Safety Manual: Motorcycle 2004 Yamaha XT660R / XT660X Service Manual (462 Pages) Overhaul-Reference
Assembly-Group: Yamaha XT660R(S) & XT660X(S) — 2004 // Architecture-Focus: Fuel Injection System Logic // Model-Specs: 660 cm³ displacement, 100.0 × 84.0 mm bore and stroke, 10.00:1 compression ratio.
| Integrated-Framework | Value | Calibration-Data |
|---|---|---|
| Engine Type | Liquid-cooled, 4-stroke, SOHC | Complete specifications provided |
| Displacement | 660 cm³ (40.27 cu·in) | Documented |
| Idle Speed Range | 1,300 ~ 1,500 r/min | Reference included |
| Oil Capacity | 2.90 L total | See Chapter 2 specifications |
| Compression Reference | 650 kPa at 800 r/min | Standard pressure data |
Providing a structural breakdown of the XT660 Series, this 462-page service reference documents the complete mechanical architecture, electrified fuel injection framework, and modular component assemblies for both carbureted and injection-equipped variants. The document covers engine and transmission systems, calling for comprehensive technical procedures across nine major chapters, and addresses cooling system architecture, electrical integration pathways, and operator maintenance protocols. The manual references torque specifications for the crankshaft assembly to ensure proper mechanical integrity, and includes wiring diagrams, diagnostic mode operations, and fail-safe action logic for the ECU self-diagnostic system.
Safety procedures are documented for brake system service, encompassing hydraulic circuit design, caliper function, and pad replacement protocols. Fluid capacities are listed for coolant circulation (1.00 L total capacity with 0.25 L reservoir reserve), fuel system architecture (15.0 L tank with 5.0 L reserve), and brake fluid specifications calling for DOT 4 grade only. Tool requirements are listed for specialized operations—including valve spring compressor sets, crankcase separators, fork seal drivers, and timing light instruments—enabling technicians to access internal engine assemblies without risk of component damage. Installation guidelines are provided for the fuel pump assembly (with gasket replacement protocol), cylinder head bolts (requiring sequential two-stage tightening to 50 Nm specification), and suspension damper rod installation using specialized holding fixtures.
Maintenance guidelines are included for the air filter element (replacement when contamination detected), drive chain tension (40.0 ~ 55.0 mm slack specification), and spark plug service (CR7E type with 0.7 ~ 0.8 mm gap adjustment). The document includes wiring schematics for the electronic fuel injection relay, crankshaft position sensor circuit topology, ignition system architecture, and multifunction meter communication protocol. Troubleshooting matrices address fault code diagnostics (code 12 through 62 with alternate operation control descriptions), sensor output voltage ranges, and component replacement criteria based on electrical continuity testing and resistance measurement protocols.
The manual documents torque specifications for the fuel injector mounting to ensure proper combustion chamber sealing and valve clearance compensation.
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