Category:
Dual-sport / Adventure Motorcycle
Design Philosophy:
Built for adventure and durability, offering a balance between on-road comfort and off-road capability.
Competitors:
Honda Transalp, Suzuki DR650, Kawasaki KLR650 (during its era)
Features:
Robust single-cylinder engine, long-travel suspension, durable construction, suitable for both on-road and off-road touring
Target Audience:
Do-it-yourself enthusiasts and professional motorcycle mechanics.
Years Covered:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
Hundreds of pages (specific count not provided, but described as comprehensive)
Content Density:
Content is highly detailed with substeps, notes, cautions, and warnings for each procedure.
Type:
Workshop Service Repair Manual
Scope:
Comprehensive Factory Service Manual covering all aspects of maintenance, repair, and troubleshooting.
Compatibility:
Compatible with all PC-based Windows operating systems and Mac.
Delivery Method:
Instant download link provided on checkout page after payment completion.
Software Requirements:
Adobe PDF Reader
Covered Systems:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Engine Rebuild:
Yes, detailed procedures for disassembly, inspection, and reassembly of engine components.
Electrical System:
Yes, includes troubleshooting, wiring diagrams, and component testing.
Frame And Bodywork:
Yes, covers frame inspection, repairs, fairing removal/installation, and body panel fitting.
Procedures:
Step-by-step repair procedures, complete disassembly, troubleshooting, electrical diagnostics, maintenance, servicing
Suspension Service:
Yes, covers fork and rear shock maintenance, adjustments, and rebuilds.
Brake System Service:
Yes, includes procedures for brake fluid replacement, caliper maintenance, and pad replacement.
Depth:
Complete factory service information, suitable for do-it-yourselfers and experienced mechanics, detailed illustrations and photos, specific substeps for repair procedures
Diagnostics:
Includes troubleshooting guides for common issues, helping to diagnose problems efficiently.
Illustrations:
Includes hundreds of photos and detailed illustrations, drawings, and enlarged insets to guide repair procedures.
Type:
Liquid-cooled, 4-stroke, DOHC, 5-valve, single-cylinder
Bore X Stroke:
100.0 mm x 84.0 mm
Horsepower Est:
~47 hp @ 6,250 rpm (Specific figure may vary slightly by year/region)
Torque Est:
~57 Nm @ 5,250 rpm (Specific figure may vary slightly by year/region)
Power Delivery Characteristics:
Torquey and tractable, suitable for off-road traction and comfortable touring.
Carburetor:
Mikuni BSR36 (single)
Fuel Type:
Unleaded gasoline
Fuel Tank Design:
Large capacity for extended touring range.
Features:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, basic indicator lights.
Features:
N/A (Modern electronic rider aids were not prevalent during this era)
Oil Change Interval:
Every 5,000 km or 6 months (Refer to manual for precise intervals and conditions)
Valve Clearance Check:
Every 10,000 km (Refer to manual for precise intervals and conditions)
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, SG, SH, SJ or higher (Refer to manual for exact specification)
Engine Oil Capacity:
Approx. 2.5 L (with filter change)
Coolant Type:
High-quality ethylene glycol-based coolant, 50% solution with distilled water (Refer to manual)
Brake Fluid Type:
DOT 4 (Refer to manual)
Fork Oil Type:
Yamaha Fork Oil (or equivalent) SAE 10W (Refer to manual for specific type and quantity)
Common Problems:
Stalling due to carburetor issues, wear in the decompression mechanism, regulator/rectifier failure, potential for worn swingarm bearings, exhaust header pipe cracks (depending on usage and maintenance)
Performance Related Issues:
Carburetor jetting can sometimes be lean from the factory, potentially requiring adjustment for optimal performance, especially at higher altitudes.
Heritage:
Yamaha has a long history in motorcycle manufacturing, known for performance and innovation across various segments, including off-road and adventure.
Evolution:
The XTZ660 Ténéré succeeded earlier Ténéré models and was known for its robust single-cylinder engine, which provided good torque and reliability for adventure touring. It featured a distinctive dual headlight fairing and a large fuel tank.
Key Changes Over Years:
Minor styling and component updates, but the core chassis and engine remained largely consistent throughout the 1991-1999 production run.
Production Period:
1991-1999
