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Yamaha · Yamaha four-stroke single (XT/TT/SR 500 1976-)

XT 660

Library entry covers 1994-2018

19 factory 34 guideline

Published source

Yamaha XT660R Owner's Manual 5VK-28199-E1 (English), periodic maintenance and lubrication chart pp.6-2 to 6-4

Factory owner's handbook. Covers XT660R (2004-2016 era), EU owner's manual 5VK-28199 (English edition E1).

Open the source

53 items for a 2016 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2016 Yamaha XT 660

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 500 km

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain (check slack, alignment, condition; adjust and lubricate). Factory: Every 500 km and after washing or riding in the rain

Every 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 5,000 km or 12 months

5 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline

Every 9,500 km or 12 months

5 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km or 12 months

4 items

Change engine oil

Engine

Factory

Manual: Engine oil (change). Factory: Every column incl. 1000 km initial; annual check
Fuel line (check hoses for cracks or damage)

Fuel and air

Factory

Factory: From 10000 km; annual check
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand (check operation, lubricate). Factory: From 10000 km; annual check
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables (lubricate). Factory: From 10000 km; annual check

Every 10,000 km

5 items

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check operation, adjust). Factory: Every column incl. 1000 km initial
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check play and roughness). Factory: Every column incl. 1000 km initial
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assembly (check operation and for oil leakage). Factory: From 10000 km
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Wheels (check runout, spoke tightness and for damage). Factory: Every column incl. 1000 km initial
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check). Factory: From 10000 km

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

3 items

Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 20,000 km

6 items

Check and adjust valve clearances

Engine

Factory

Manual: Valves (check valve clearance, adjust). Factory: Marked at 20000 km and 40000 km; dealer item
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug (check condition, clean and regap). Factory: Marked at 10000 km and 30000 km
Replace oil filter

Engine

Factory

Manual: Engine oil filter element (replace). Factory: Marked 1000 km initial, 20000 km, 40000 km
Replace spark plugs

Engine

Factory

Manual: Spark plug (replace). Factory: Marked at 20000 km and 40000 km
Replace air filter element

Fuel and air

Factory

Manual: Air filter element (replace). Factory: Marked at 20000 km and 40000 km; more often in wet or dusty areas
Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate with lithium-soap-based grease). Factory: Every 20000 km

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (change). Factory: Every two years, with brake master cylinder internal components (chart note)

Every 3 years

1 item

Replace coolant

Engine

Factory

Manual: Cooling system (change). Factory: Every 3 years; check level every 10000 km and annually

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses (replace). Factory: Every 4 years; check every 10000 km and annually
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.