Yamaha XT 660 Z TENERE 600 2008-2009 Service Repair Manual & Parts Catalogue XT660Z

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🏷️ Basic Information Identification Make: Yamaha Model: XT660Z Ténéré Model Code: XT660Z Generation: First Generation (2008-2009 model years) Engine Variant Covered: Single-cylinder, 4-stroke, liquid-cooled, SOHC, 4-valve Codes Chassis Code General:...

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Taper: Motorcycle

Distributeur:

UGS: 244479

Mots clés: 2008 2009 Motorcycle Motorcycles XT 660 Z TENERE XT Models XT660Z Yamaha

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT660Z Ténéré

Model Code:

XT660Z

Generation:

First Generation (2008-2009 model years)

Engine Variant Covered:

Single-cylinder, 4-stroke, liquid-cooled, SOHC, 4-valve

Codes

Chassis Code General:

Engine Code General:

👋 Introduction

Market Position

Vehicle Segment:

Adventure Touring Motorcycle

Target Audience:

Riders seeking a reliable, go-anywhere motorcycle for commuting, touring, and light off-road exploration.

Competitive Analysis

Key Competitors:

BMW F650GS, Kawasaki KLR650, Honda Transalp (in markets where available).

Market Differentiation:

Ténéré's focus on robustness, long-distance comfort, and Yamaha's reputation for reliability in the dual-sport segment.

Key Features

Motorcycle Design Philosophy:

Combines the versatility of an adventure bike with the practicality of a daily rider, emphasizing durability and ease of maintenance.

Manual Value Proposition:

Provides owners and technicians with the official, detailed information needed to maintain, troubleshoot, and repair the XT660Z Ténéré, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual & Parts Catalogue

Primary Coverage Years:

2008-2009

Extended Coverage Notes:

Service Manual Edition 2008 is confirmed to work perfectly for 2009 models.

Page Count

Total Pages:

> 400

Language

Language:

English (ENG)

Format

File Format:

Delivery Method:

ZIP archive

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine disassembly, assembly, inspection, and repair procedures for the 1-cylinder 660cc engine.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, and related components.

Cooling System:

Radiator, cooling fan, water pump, coolant flow, and thermostat operation.

Ignition System:

ECU, ignition coils, spark plugs, and timing.

Transmission System:

Clutch operation, gear selection, gear ratios, internal transmission components, and maintenance.

Frame And Suspension:

Frame construction, front fork (telescopic, upside-down), rear shock absorber (monoshock), linkages, bearings, and adjustments.

Wheel And Tire System:

Wheel hub, spokes, rims, tire specifications, balancing, and replacement.

Braking System:

Front and rear disc brakes, calipers, master cylinders, brake lines, fluid specifications, and bleeding procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, tail light, indicators), horn, and wiring harness.

Exhaust System:

Exhaust pipes, catalytic converter (if applicable), muffler, and mounting.

Bodywork And Fairings:

Removal, installation, and repair of all body panels, fairings, seat, and fuel tank cover.

Controls And Instruments:

Handlebars, levers, throttle control, brake controls, dashboard, indicators, and switches.

Parts Catalogue:

Comprehensive parts listings with diagrams and part numbers for all major components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication, tire pressure checks, and general inspections.

Troubleshooting:

Diagnostic procedures for common problems, fault finding, and symptom-based solutions.

Disassembly And Reassembly:

Step-by-step instructions for taking apart and putting back together major vehicle systems.

Component Testing:

Procedures for testing the functionality of electrical components, sensors, and mechanical parts.

Adjustments:

Instructions for adjusting clutch, throttle cables, suspension settings, and idle speed.

Repair And Rebuild:

Detailed guidance for repairing or rebuilding major engine, transmission, and suspension components.

Torque Specifications:

Essential torque values for all critical fasteners during assembly and disassembly.

Wiring Diagrams:

Complete and detailed wiring diagrams for all electrical systems, aiding in diagnostics and repair.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic maintenance to advanced engine rebuilds and electrical system diagnostics.

Illustration Quality:

High Quality: Features hundreds of detailed illustrations, diagrams, and exploded views.

Diagnostic Capability:

Advanced: Includes diagnostic charts and troubleshooting flowcharts for systematic problem identification.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF, assuming it's not a pure image scan.

Print Quality

Printability:

Fully Printable

Quality Descriptor:

High Quality

Binding Type

Binding Type Digital:

N/A (Digital PDF)

Digital Organization:

Bookmarked for easy navigation.

Paper Type

Paper Type Digital:

N/A (Digital PDF)

Completeness

Manual Completeness:

Genuine Factory Service Manual & Parts Catalogue, indicating completeness for the specified model years.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Cooling System:

Liquid-cooled

Valve Train:

SOHC, 4 valves

Bore X Stroke:

100.0 mm x 84.0 mm

Displacement:

660 cc

Compression Ratio:

10.0:1

Performance

Claimed Horsepower:

47.5 PS (34.9 kW) @ 6,000 rpm (approximate, may vary by market)

Claimed Torque:

6.1 kgf·m (60 N·m, 44 lb·ft) @ 5,250 rpm (approximate, may vary by market)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Throttle Body Size:

44 mm

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

23 Liters (approximate)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multiple disc

Final Drive:

Chain

Features

Gear Ratios Overview:

The manual will detail the specific gear ratios for each of the 5 speeds, crucial for performance tuning and maintenance.

Clutch Maintenance:

Procedures for clutch lever free play adjustment, clutch disc wear inspection, and replacement.

📐 Dimensions

Exterior

Overall Length:

2,250 mm

Overall Width:

870 mm

Overall Height:

1,445 mm

Seat Height:

895 mm

Wheelbase:

1,490 mm

Ground Clearance:

260 mm

Weights

Wet Weight:

205 kg (approximate, with all fluids and full tank)

Dry Weight:

183 kg

Front Tire Size:

90/90-21M/C 54S

Rear Tire Size:

130/80-17M/C 65S

Wheel Bolt Pattern Front:

Spoked wheel with a single disc brake, hub details in manual.

Wheel Bolt Pattern Rear:

Spoked wheel with a single disc brake, hub details in manual.

🛡️ Safety Features

Ratings

Safety Certification General:

Typically meets regional homologation standards (e.g., Euro 3, DOT).

Active Features

Braking System Type:

Hydraulic disc brakes front and rear.

ABS Availability:

ABS was an optional feature on some models/markets.

Passive Features

Lighting System:

Halogen headlight, LED tail light, and turn signals for enhanced visibility.

Chassis Design:

Steel semi-double cradle frame designed for stability and durability.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital LCD instrument cluster displaying speed, RPM, fuel level, odometer, trip meters, clock, and warning lights.

Driver Assistance

ABS Option:

Optional ABS system available on select models, which can be diagnosed and serviced using the manual.

Connectivity

Connectivity Features:

None in the modern sense; this is a mechanically focused adventure motorcycle.

Engine Management

Efi System:

Advanced electronic fuel injection system for optimal performance, fuel efficiency, and emissions control, detailed in the manual.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 km or 6 months (refer to manual for precise Yamaha recommendation).

Air Filter Inspection:

Recommended every 10,000 km, or more frequently under dusty conditions.

Spark Plug Replacement:

Refer to manual, typically around 20,000 km or as needed based on inspection.

Valve Clearance Check:

Typically at 20,000 km or 40,000 km intervals, depending on manufacturer specifications. The manual will detail the exact interval and procedure.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment are critical. Intervals depend on usage, but lubrication every 500-1000 km is common.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API Service SG or higher, or JASO MA.

Engine Oil Capacity:

Approx. 2.4 Liters without filter change, 2.6 Liters with filter change (verify in manual).

Coolant Type:

Permanent type anti-freeze coolant (e.g., ethylene glycol based) with distilled water in a 50:50 mix.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch wear, chain and sprockets, front fork seals (due to off-road use), and wheel bearings.

Potential Electrical Gremlins:

While generally reliable, some owners report occasional issues with electrical connectors or the starter relay; the manual's wiring diagrams are key here.

Engine Longevity:

The 660cc single-cylinder engine is known for its durability when properly maintained. The manual will guide on how to ensure this.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Company has a long-standing reputation for innovation, performance, and reliability in motorcycle manufacturing, dating back to the 1950s.

Model Evolution

Ténéré Lineage:

The Ténéré nameplate has a rich history in rally racing and adventure touring, originating with the XT500 and XT600 models that dominated early Paris-Dakar rallies.

Xt660Z Introduction:

The XT660Z Ténéré was reintroduced to the market in 2008 as a modern iteration of the classic adventure bike, utilizing Yamaha's then-current XT660 platform.

Production

Manufacturing Location:

Typically manufactured in Japan or at Yamaha's international assembly plants.

Model Production Years:

The XT660Z Ténéré was produced from 2008 to 2016 in various iterations and markets.

🏆 Awards & Recognition

Recognitions

Model Reputation:

The XT660Z Ténéré has earned a reputation among riders for its ruggedness, go-anywhere capability, and comfortable touring ergonomics, often praised in adventure motorcycling forums and reviews.

Brand Awards General:

Yamaha consistently receives awards for engine performance, reliability, and innovation across its motorcycle range.