Yamaha XTZ660 Tenere 1993-1996 Service Repair Factory Manual

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Taper: Motorcycle

Distributeur:

UGS: 57992

Mots clés: 1993 1994 1995 1996 Marine Motorcycle Sterndrive XTZ660 Tenere Yamaha

Variantes de produits

Description

The Yamaha XTZ660 Tenere, produced between 1989 and 1997, is a versatile dual-sport motorcycle renowned for its robust engineering and adventure-ready design. Built for riders who seek to explore both paved roads and off-road trails, this first-generation model embodies Yamaha's rich heritage in rally and adventure motorcycling. Its liquid-cooled, 660cc single-cylinder engine, paired with a 5-speed transmission and a durable steel frame, provides a reliable and capable platform for touring and exploration. The XTZ660 Tenere is characterized by its spoked wheels, ample fuel capacity, and a design focused on rider control and stability across varied terrains. This comprehensive service and workshop manual is meticulously crafted to guide owners and technicians through the maintenance, repair, and troubleshooting of the Yamaha XTZ660 Tenere. It covers all essential systems, including the engine, transmission, drivetrain, electrical components, chassis, suspension, steering, and braking systems. The manual details routine maintenance procedures, provides step-by-step diagnostic guidance for mechanical and electrical issues, and offers in-depth instructions for component repair and rebuilds. With factory-level detail, including torque specifications, diagrams, and illustrations, this manual is an indispensable resource for ensuring the optimal performance and longevity of your XTZ660 Tenere.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XTZ660 Tenere

Model Designation:

Tenere

Codes

Chassis Code:

Generation

Generation Name:

First Generation

Generation Years:

1989-1997

👋 Introduction

Market Position

Category:

Dual-Sport / Adventure Motorcycle

Target Audience:

Riders seeking adventure, touring capabilities, and off-road versatility.

Competitive Analysis

Segment Competitors:

Honda Africa Twin (later models), Suzuki DR650, Kawasaki KLR650 (though often larger displacement).

Key Features

Motorcycle Purpose:

Designed for both on-road touring and light to moderate off-road exploration.

Manual Value Proposition:

Provides factory-level repair and maintenance guidance, enabling owners to perform tasks that save significant cost compared to dealer servicing.

📋 Manual Details

Coverage Areas

Product Name:

Yamaha XTZ660 Tenere 1993-1996 Service Repair Factory Manual PDF Download

Applicable Years:

1993, 1994, 1995, 1996

Primary Focus:

Service, Repair, Workshop

Page Count

Estimated Page Count:

Extensive (Typical for Factory Service Manuals, often 300+ pages)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Complete overhaul, diagnostics, performance tuning, engine removal/installation, lubrication, cooling system, fuel system, intake and exhaust.

Transmission Drivetrain:

Transmission internal inspection and repair, clutch operation, drive chain maintenance, sprocket replacement, gearbox lubrication.

Electrical System:

Wiring diagrams, starter system, charging system, ignition system, lighting, instrumentation, troubleshooting electrical faults.

Chassis Suspension Steering:

Front fork service, rear shock absorber maintenance, steering head bearing adjustment, wheel and tire service, suspension geometry.

Braking System:

Brake fluid replacement, caliper service, master cylinder overhaul, brake pad replacement, disc inspection.

Bodywork Frame:

Fairing removal and installation, panel repairs, seat servicing, frame inspection, mounting points.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, fluid level checks, spark plug replacement.

Diagnostic Troubleshooting:

Step-by-step fault finding for mechanical and electrical issues, diagnostic codes, common problems.

Repair Rebuild:

Detailed instructions for component disassembly, repair, reassembly, and calibration for all major systems.

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics.

Detail Level:

Includes torque specifications, clearance measurements, timing settings, electrical resistance values, and diagnostic procedures.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Printability:

Fully printable, allowing users to print specific pages or sections as needed.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital Document)

Features

Searchability:

Likely searchable text within the PDF for quick information retrieval.

Illustrations:

Includes diagrams, illustrations, and schematic drawings to aid understanding.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, 5-valve, single-cylinder

Displacement:

660 cc (659 cm³)

Performance

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

9.1:1

Horsepower Approx:

48.2 HP @ 6,000 RPM (as per typical specifications for this era and engine)

Torque Approx:

5.8 kgf·m @ 5,000 RPM (as per typical specifications for this era and engine)

Fuel System

Fuel Delivery:

Carburetor (e.g., Mikuni BSR32 for earlier models, possibly updated)

Fuel Type:

Unleaded gasoline

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multiple-disc

Features

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length Approx:

2,215 mm (87.2 in)

Width Approx:

830 mm (32.7 in)

Height Approx:

1,425 mm (56.1 in)

Weights

Dry Weight Approx:

187 kg (412 lbs)

Wet Weight Approx:

206 kg (454 lbs)

Fuel Capacity:

20 Liters (5.3 US gal)

Wheels Tires

Front Tire Size:

90/90-21

Rear Tire Size:

130/80-17

Wheel Type:

Spoked wheels

🛡️ Safety Features

Ratings

Overall Safety Design:

Focus on rider control and stability in varied conditions, incorporating robust suspension and braking for its class.

Active Features

Braking System:

Front: Disc brake, Rear: Disc brake

Passive Features

Frame Construction:

Steel semi-double cradle frame for rigidity and durability.

💡 Technology Features

Infotainment

Display System:

Analog speedometer and tachometer, basic indicator lights.

Driver Assistance

Rider Aids:

None (This era of motorcycle predates widespread electronic rider aids like ABS or traction control).

Connectivity

Smartphone Integration:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual (Typically every 3,000-5,000 km or 6 months)

Air Filter Cleaning:

Refer to manual (Periodic inspection and cleaning/replacement)

Spark Plug Replacement:

Refer to manual (Typically every 10,000-20,000 km)

Fluid Specifications

Engine Oil Type:

Refer to manual (e.g., SAE 10W-40 API SG or higher motorcycle-specific oil)

Engine Oil Capacity:

Refer to manual (Approx. 2.4 - 2.6 Liters with filter change)

Coolant Type:

Refer to manual (Ethylene glycol based antifreeze coolant)

Brake Fluid Type:

Refer to manual (DOT 3 or DOT 4)

Known Issues

Common Wear Items:

Clutch wear, drive chain and sprockets, fork seals, voltage regulator (early models), stator.

Carburetor Tuning:

Can require periodic adjustment or cleaning due to age and fuel quality, especially if stored for extended periods.

Electrical Connections:

Corrosion in connectors can lead to intermittent electrical issues, requiring inspection and cleaning.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha has a long history of producing reliable and performance-oriented motorcycles across various segments, including adventure touring.

Model Evolution

Tenere Lineage:

The Tenere nameplate is synonymous with Yamaha's rally and adventure heritage, stemming from the Paris-Dakar rally success of earlier models like the XT500 and XTZ750.

Xtz660 Placement:

The XTZ660 was developed to offer a more accessible, single-cylinder adventure platform compared to the V-twin XTZ750 Super Tenere, focusing on off-road capability and fuel efficiency.

Production

Production Years:

1989-1997 (First Generation)

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this model are not readily cited, the Tenere line generally received recognition for its adventure capabilities and durability.

Ratings

Owner Reviews:

Generally well-regarded by owners for its go-anywhere attitude, reliability, and ease of maintenance, though often considered underpowered by some for heavily loaded touring.