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2004 Yamaha XT660R

Yamaha XT660R

Yamaha's name has been synonymous with big singles for nearly 30 years, and the all-new XT660R is the very latest addition to the long and distinguished line of XT adventure models. Its 660cc liquid-cooled fuel-injected engine is tuned to deliver high levels of mid-range torque for rapid acceleration, and the state-of-the-art dual rail chassis and longtravel suspension give agile handling in a variety of conditions. A newly designed front fender has a high level front section and tyre-hugging rear section, whilst the dual up-mufflers make for a clean and stylish rear end - and to keep the rider informed there is a comprehensive multi-function LCD instrumentation panel. For detailed information please refer to the full Yamaha XT660R press release.

Yamaha's XT600 has established a strong and loyal following amongst big single riders who value and appreciate its remarkable all-round versatility and legendary durability, as well as its special character. Perhaps above all though, it is the XT's reputation for being a fun bike to ride in virtually any situation that has made this gutsy motorcycle one of Yamaha's most successful models.

Now, three decades on from the launch of the original ground-breaking XT500, the legendary XT brand is reborn in the shape of the exciting new XT660R. Featuring a highly advanced fuel-injected engine and sophisticated chassis, this all-new machine runs with state-of-the-art technology that offers today's rider higher levels of performance, roadholding and comfort.

Yet, at the same time as being the most advanced and sophisticated XT ever produced, the new XT660R has also inherited the very heart and soul of its legendary predecessors that have made the XT such an important part of motorcycle history. Its gutsy character, rugged good looks and 'do anything' nature look sure to endear this charismatic new motorcycle not only to existing XT owners and other single cylinder bikers, but also to a whole new generation of riders who are searching for a genuine all-round motorcycle possessing the genes of a thoroughbred and backed up by a reputation forged over nearly 30 years that is second to none.

The letters 'XT' are amongst the most famous and most respected in the world of motorcycling, and they have been worn with pride by a succession of highly successful Yamaha dual purpose models spanning three decades. With X standing for cross, and T standing for trail, the XT range has opened up a new world of total freedom for nearly 400,000 riders all over Europe for nearly 30 years, and the brand has come to epitomise the essential spirit of fun, freedom and adventure that attracts so many people to the world of motorcycling.

When Yamaha launched the original XT500 in 1976, few people could have imagined how one machine could have such an enormous effect on the shape of motorcycling in the decades to come.

As the first 4 stroke single ever produced by Yamaha, the XT500 has a special place in the history of the company. But perhaps even more significant than its place in Yamaha's corporate history books is the influence the original XT500 had on the whole world of motorcycling. In the late 1970s the vast majority of dual purpose bikes were lightweight 2 strokes, and so the arrival of a 4 stroke big single opened up an exciting new world of possibilities.

With its mechanical strength, rugged chassis, high levels of torque and greater fuel efficiency than its 2 stroke counterparts, the XT500 in 1976 was soon recognised as being the ideal machine for long distance rallying. It is widely recognised that the XT played a major role in making the dream of the very first Paris-Dakar Rally come true for the late Thierry Sabine in 1979. And the rest is history!

Since the first event, XT and XTZ-based machines have won this gruelling rally a total of nine times, making Yamaha the most successful manufacturer in what is widely regarded as the world's toughest motorsport event.

The original XT500 will go down in history for many reasons. As well as being Yamaha's first 4 stroke big single which played a pivotal role in making the Paris-Dakar Rally a reality, the XT500 was also one of Yamaha's longest running production models which was still being manufactured right up until 1989, 13 years after its introduction. In 1982 Yamaha launched the XT550 which featured an advanced new chassis equipped with a motocross-derived Monoshock rear suspension, and this was followed in 1983 by the XT600Z TÚnÚrÚ whose large capacity fuel tank was inspired by Yamaha's Paris-Dakar winning factory machines. Introduced in the late 1980s, the XT600 was quick to establish itself as one of Yamaha's most popular middleweights, and during the 1990s the model underwent a number of technical and stylistic changes, culminating in the XT600E that came to the end of its long and successful production run in 2003.

New XT660R target market

With its new liquid-cooled engine, lightweight chassis, high specification brakes and improved levels of rider comfort, the new XT660R has been designed to attract an even broader spectrum of riders than its highly successful air-cooled predecessor.

The new XT660R is clearly aimed at riders who need a machine that can handle everything from poorly surfaced rural roads and trails through to urban streets and flowing open roads. With a genuine on/off ability combined with strong low and high speed performance and sharp looks - and reinforced by the high esteem in which the XT brand is held throughout Europe - the new XT660R raises the stakes in this sector of the marketplace.

The second customer group consists of predominantly urban based riders who use their machine for daily commuting as well as leisure riding out of town. These riders will be attracted by the higher levels of performance, agility and comfort offered by the new XT660R, and although many will never explore all the potential offered by its dual purpose abilities, they will nevertheless benefit from the easy handling, upright riding position and high torque output that make the new XT660R such a strong performer in urban situations.

New 660 cc liquid-cooled engine

The new XT is powered by an all-new fuel-injected single cylinder engine that has been designed to deliver massive torque in the low- to mid-speed range, making this a truly versatile machine that excels in a very wide range of conditions. Running with bore and stroke dimensions of 100 x 84 mm, the compact new powerplant is the most advanced big single ever produced by Yamaha, and in technological terms the XT660R engine is a generation ahead of the air cooled design featured on the XT600E. The priorities of the design team were to produce a compact, efficient and relatively lightweight engine that would deliver massive low- to mid-speed torque across a wide operating range, and would also comfortably surpass EU-2 emissions regulations.

The new XT660R is equipped with a fuel injection system which delivers increased performance with exceptional throttle response, and this efficient new system also plays an important role in reducing emissions to levels well below those set by EU-2 standards. For highly efficient intake processes a long 82.1 mm injector featuring twelve holes feeds the precisely controlled fuel supply via a big bore 44 mm throttle body into the newly designed cylinder head.

Complementing the XT's fuel injection system is a newly designed cylinder head that offers higher levels of intake and exhaust gas flow efficiency. The new SOHC 4-valve head runs with large diameter 38 mm intake valves and 32 mm diameter exhaust valves, with both pairs of valves angled at 20 degrees for optimal efficiency.

In addition to these performance enhancing designs, the engine's friction-related power losses are minimised by the use of roller bearings in the rocker arms, making this new SOHC cylinder head one of the lightest, most compact and most efficient in the class.

Every effort has been made wherever possible to reduce engine weight and increase efficiency, and the new XT660R is fitted with an automatic decompressor mechanism. Its design is similar to that featured on Yamaha's YZ and WR competition models, is therefore lightweight and it makes for easy starting.

The new aluminium cylinder runs with a 100 mm bore and 84 mm stroke, and features a ceramic composite plated bore that offers improved heat dissipation and helps reduce weight. Running in the low-friction plated cylinder is a lightweight forged piston whose low reciprocating weight makes for responsive pick up at all speeds.

The high efficiency 10:1 compression ratio 4-valve cylinder head discharges gases through a free-breathing dual exhaust system manufactured from stainless steel. Twin header pipes flow into dual large capacity up-mufflers equipped with catalysers which ensure that the new XT660R meets EU-2 emissions regulations.

Combined with the new fuel injection system, as well as the 4-valve cylinder head and lightweight forged piston, this new exhaust system makes Yamaha's new 660 cc engine the most powerful and responsive big single ever used on a road-going production Yamaha.

To ensure that this new big single runs as cleanly as possible it is fitted with an air induction system that introduces fresh air into the exhaust system when any unburned gases are detected. The introduction of air minimises emissions to the lowest level ever seen on a Yamaha single, allowing the new XT660R to fall well within EU-2 standards.

Yamaha's engineers have fitted a relatively light 130 mm diameter rotor, and its lower weight makes for reduced inertial mass, which translates into excellent throttle response over a wide range of engine speeds.

Complementing the new higher powered fuel-injected engine is a completely redesigned 5-speed transmission that has been developed to offer smooth and efficient operation in all riding conditions.

All gear wheels from second through to fifth feature five gear wheel dogs (compared to three on previous Yamaha models), whilst first gear runs with four dogs. In addition to the uprated gear wheels, three shift fork bars (instead of two) are featured, whilst the shift cam segment shape has been optimised, and finally the XT660R's shift shaft runs on two bearings. As well as ensuring slick shifting, these new features also make this one of the strongest transmissions ever featured on a Yamaha single.

Every effort has been made to reduce the weight of components such as the piston, cylinder and cylinder head. Our engineers have also succeeded in minimising engine dimensions wherever possible, and its compact crankcase design has given our designers greater freedom in the construction of a lightweight, agile handling chassis.

Engine technical highlights

  • 660 cc liquid-cooled single cylinder 4 stroke
  • New SOHC 4-valve cylinder head design
  • Rocker arms equipped with roller bearings
  • 10:1 compression ratio
  • Forged piston and ceramic composite plated cylinder
  • Compact radiator with cooling fan
  • High torque output across wide operating range
  • Fuel injection with big bore 44 mm throttle body
  • Dual exhaust ports
  • Dual stainless steel up-mufflers with dual catalysers
  • Complies with EU-2 emissions regulations
  • Compact overall dimensions for a 660 cc engine
  • Lightweight rotor
  • Durable slick-shifting transmission
  • Separate clutch cover for easy maintenance
  • New lightweight high-rigidity chassis
  • In the same way that the new liquid-cooled fuel-injected engine represents a major leap forward in the evolution of the XT series, the high-specification chassis gives this new generation all- rounder even greater potential and wider appeal.

    HIGH RIGIDITY FRAME

    The new XT660R is equipped with a completely redesigned chassis that has been designed to offer exceptional rigidity which is particularly beneficial in the higher speed ranges, thereby expanding the versatility of this exciting new big single.

    INCREASED FUNCTIONALITY

    Whereas previous XT models have featured a single top frame tube, the new XT660R is equipped with dual tank rails that greatly increase overall chassis rigidity. This increased strength allows the XT rider to make full use of the higher power output of the new liquid cooled engine, giving the new XT660R an improved adventure touring function at higher speeds.

    EASY MANOEUVRABILITY

    However, while the new dual tank rail frame has been designed to offer higher levels of rigidity, its weight and dimensions have been kept to a minimum so that the XT660R retains the agile handling and nimble low speed manoeuvrability that has made the XT brand such a strong performer in congested urban streets.

    Overall chassis weight is kept low by using the 660 cc engine as a stressed member, and for smooth and light steering characteristics the head pipe is equipped with taper roller bearings.

    INTEGRAL OIL TANK

    The new frame incorporates an oil tank behind the head pipe, and the tank's position at the front of the machine in an area of high air flow makes for excellent heat dissipation to give consistently strong engine performance.

    LONG TRAVEL 43 mm DIAMETER FRONT FORKS

    The XT660R's Paioli front forks are equipped with large diameter 43 mm tubes that complement the stiff chassis to give firm handling at higher speeds together with easy manoeuvrability and smooth suspension action in urban situations. These high specification forks give 225 mm of front wheel travel to ensure a comfortable ride on the street, and the generous suspension stroke combined with the flex-resistant 43 mm tubes underline the XT's genuine ability to handle off road terrain.

    MONOCROSS REAR SUSPENSION

    The Monocross rear suspension system features a compact single shock absorber operated by a strong box section swingarm via a rising rate linkage. This rugged set-up gives a full 200 mm of wheel travel, ensuring that XT660R riders and passengers enjoy a comfortable journey over a variety of road surfaces. This proven system features a 5-step preload adjuster, allowing quick and easy changes of suspension settings to suit the conditions.

    LARGE DIAMETER 298 mm FLOATING FRONT DISC

    As already mentioned, the new more powerful engine and higher rigidity chassis expand the performance horizons of the new generation XT660R, and to match this increased potential a new large diameter front disc brake is fitted. The 298 mm floating front disc is slowed by a Brembo 2-piston caliper equipped with different diameter pistons of 30 mm and 32 mm, and this high specification arrangement offers the XT660R rider high levels of braking performance together with accurate feel over a wide range of riding speeds. Complementing the large diameter front brake is a 245 mm rear disc that is slowed by a single piston Brembo caliper, which, like the front brake, offers a progressive action together with plenty of feedback to the rider.

    15-LITRE FUEL TANK

    The XT's slim, compact and stylish 15-litre fuel tank gives a good operating range, and its relatively short front/rear dimensions allow the rider to adopt a natural, upright seating position with their knees tucked close in to the chassis.

    LIGHTWEIGHT ALUMINIUM WHEEL RIMS

    To ensure that unsprung weight is kept to a minimum, the new XT660R runs with a 21 inch front wheel and 17 inch rear wheel equipped with aluminium rims. By keeping unsprung weight low, the front and rear suspension action is enhanced, giving a higher quality ride both on and off road.

    NEW STYLE FRONT FENDER AND FORK PROTECTOR

    The new XT660R is the first Yamaha to be equipped with a new front fender and fork protector system which combines the rugged image of a high level system with the practicality of a conventional low level fender.

    The front section of this system features a high level dual-purpose style fender incorporating lightweight fork protectors that help shield the 43 mm tubes from road debris. Meanwhile, the rear section of the fender immediately behind the front forks is a low level design that is mounted close to the 21 inch front wheel, and this does an effective job in keeping dirt and spray off the front of the engine. Another advantage of this system is that it helps to enhance engine running efficiency by allowing unimpeded fresh air to flow straight into the radiator and also past the in-frame oil tank.

    MULTI-REFLECTOR HEADLIGHT AND COMPACT WINDSCREEN

    The all-new multi-reflector headlight runs with a powerful 60/55 W bulb for good night time visibility, and a compact windscreen helps deflect wind away from the rider's upper body for improved comfort. To underline the bike's fresh new looks the compact flashers now feature clear lenses and orange coloured bulbs.

    INTEGRATED IMMOBILISER SYSTEM

    To help protect the machine from theft there is a new immobiliser system built into the main ignition switch. Once the keys are removed by the rider the immobiliser automatically sets itself, making the XT660R virtually impossible to start.

    U-LOCK STORAGE SPACE

    In addition to its electronic anti-theft system, the XT660R also features a U-lock storage space under the dual seat. When used in association with the immobiliser, the U-lock helps to deter potential thieves.

    MULTI-FUNCTION INSTRUMENT PANEL

    The high specification instrumentation on the new XT is all new, and its sophisticated multi-function displays and digital speedometer reflect the greatly enhanced specification of this new generation big single. At the centre of the panel is the LCD speedometer, and next to this are displayed a clock, tripmeter 1, and a multi-function display consisting of a tripmeter 2, odometer and fuel tripmeter.

    Warning lights display information on engine temperature, engine status, turn signals, fuel level, high beam and neutral, and there is also an indicator light to confirm the status of the XT's immobiliser system.

    Chassis Technical Highlights

  • Tubular steel diamond type frame
  • Dual tank rails
  • Taper roller steering head bearings
  • 43 mm diameter Paioli front forks
  • 225 mm front wheel travel
  • 5-step preload adjustable Monocross rear suspension
  • 200 mm rear wheel travel
  • Lightweight aluminium wheel rims, 21" front, 17" rear
  • 298 mm floating front disc brake
  • 2-piston Brembo front caliper
  • 245 mm rear disc brake
  • Single piston Brembo rear caliper
  • 15-litre fuel tank with integral fuel pump
  • New design front fender and fork protector
  • Low level rear front fender
  • Multi-reflector 60/55 W headlight
  • Compact headlight cowl with windscreen
  • Multi-function LCD digital speedometer
  • Main switch with immobiliser
  • U-lock storage space

    COLOURS

  • Racing Blue
  • Yamaha Black

    Rebirth of the legend

    Born nearly 30 years ago, the original XT has had an enormous influence on the development of motorcycling within Europe. Spanning the 70s, 80s, 90s and now running into the 21st century, the XT brand has come to represent everything that is best about motorcycling. Rugged and reliable, fun and adventurous, the XT means many things to many people.

    Now, as the air-cooled model comes to the end of its illustrious production run, Yamaha introduce a new generation liquid cooled successor that is ready to offer the XT experience to a wide spectrum of riders who appreciate the essential values of motorcycling. With its more powerful liquid-cooled fuel-injected engine, high rigidity chassis, state-of-the-art suspension and high specification braking systems, the new XT660R offers even greater sports riding potential, and yet retains the core values of the XT brand.

  • Engine Type - Liquid-cooled, 4-stroke, SOHC, 4 valves
  • Displacement - 659 cc
  • Bore and Stroke - 100 x 84 mm
  • Compression ratio - 10:1
  • Max. Power - 35.3 kW (48 HP) @ 6000 rpm
  • Max. Torque - 58.4 Nm (5.95 kg-m) @ 5250 rpm
  • Lubrication - Dry sump
  • Fuel supply Fuel injection, 44 mm throttle body
  • Clutch type - Wet, multiple disc
  • Ignition - TCI
  • Starting system - Electric
  • Transmission - Constant mesh, 5 speed
  • Final transmission - Chain
  • Gear ratio - 1 2.500, 2 1.625, 3 1.150, 4 0.909, 5 0.769
  • Primary reduction ratio - 2.083
  • Secondary reduction ratio - 3.000
  • Frame - Steel tubular diamond frame with dual tank rails
  • Front suspension - Telescopic fork, ° 43 mm
  • Rear suspension - Monocross with linkage
  • Front wheel travel - 225 mm
  • Rear wheel travel - 200 mm
  • Caster angle - 28
  • Trail - 118 mm
  • Front brake - Single floating disc, ° 298 mm
  • Rear brake - Single disc, ° 245 mm
  • Front tyre - 90/90-21M/C 54S
  • Rear tyre - 130/80-17M/C 65S
  • Rim size front - 21 x 1.85
  • Rim size rear - 17 x MT2.75
  • Overall length - 2240 mm
  • Overall width - 850 mm
  • Overall height - 1235 mm
  • Seat height - 855 mm
  • Wheelbase - 1500 mm
  • Min. ground clearance - 200 mm
  • Dry weight - 165 kg
  • Fuel tank capacity - 15 litres (reserve 3.5 litres)
  • Oil (tank) capacity - 2.9 litres
  • XT660R New model Yamaha Black, Racing Blue