Yamaha XT660Z 2008-2012 Workshop Service Manual Repair

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Mots clés: 2008 2009 2010 2011 2012 Misc Motorcycle Motorcycles XT660Z Yamaha

Variantes de produits

Description

The Yamaha XT660Z Ténéré is a dual-sport adventure motorcycle produced from 2008 to 2012, built upon Yamaha's long-standing legacy of rugged and capable off-road machines. This model, powered by a 660 cc single-cylinder engine with electronic fuel injection, is designed for both long-distance touring and tackling varied terrains. Its robust steel-tube frame, upright riding position, and substantial 23-liter fuel tank emphasize its go-anywhere attitude and reliability, making it a favored choice for adventure riders and those seeking a dependable machine for diverse riding conditions. This comprehensive Workshop Service Manual provides in-depth guidance for the Yamaha XT660Z Ténéré, covering all aspects of maintenance, troubleshooting, and repair. Within its pages, you will find detailed procedures for engine disassembly and assembly, transmission servicing, chassis maintenance, brake system overhauls, and electrical system diagnostics, including wiring diagrams. The manual also addresses scheduled maintenance, fluid specifications, and common issues, offering step-by-step instructions, torque values, and diagrams to assist owners, mechanics, and technicians in keeping the XT660Z Ténéré in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT660Z Ténéré

Model Code:

XT660Z

Production Years Covered:

2008, 2009, 2010, 2011, 2012

👋 Introduction

Market Position

Category:

Dual-sport / Adventure Motorcycle

Target Audience:

Adventure riders, off-road enthusiasts, touring riders, DIY mechanics.

Competitive Analysis

Competitors:

BMW F650GS, Kawasaki KLR650, Honda Transalp (older models), Suzuki V-Strom 650.

Key Features Of Vehicle

Engine Type:

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

Design Philosophy:

Robustness, reliability, long-distance capability, adaptable to various terrains.

📋 Manual Details

Coverage Areas

Language:

English

Manual Type:

Workshop Service Manual / Repair Manual

Format:

PDF Download

Coverage Scope:

Comprehensive for all maintenance, troubleshooting, and repair procedures.

📖 Manual Coverage

Systems Covered

Engine:

Disassembly, assembly, inspection, lubrication, cooling, fuel injection, ignition, exhaust.

Transmission:

Clutch, gearbox, operation, inspection, repair.

Chassis:

Frame, suspension (front and rear), steering, swingarm, bearings.

Brakes:

Hydraulic system, front and rear calipers, master cylinders, bleeding procedures, pad replacement.

Electrical System:

Wiring diagrams, battery, charging system, ignition system, lighting, instrumentation, ECU.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injection system (throttle body, injectors).

Cooling System:

Radiator, cooling fan, coolant specifications, circulation.

Exhaust System:

Muffler, catalytic converter, heat shields, gasket replacement.

Wheels And Tires:

Wheel removal/installation, tire pressure, balancing, spokes maintenance.

Procedures Included

Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, lubrication points.

Troubleshooting:

Diagnostic charts for common problems, fault finding procedures, error codes (if applicable).

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly.

Diagnostics:

Engine performance diagnostics, electrical system testing, component testing.

Technical Depth

Depth:

In-depth, covering everything from basic adjustments to complete engine and transmission rebuilds.

Detail Level:

Detailed diagrams, torque specifications, clearance measurements, and special tool requirements.

📊 Manual Specifications

File Format

Type:

Searchable:

Likely searchable text, enabling quick information retrieval.

Printable:

Designed for printing, allowing for physical reference during work.

Quality:

Professional quality, clear schematics and text.

File Size:

Typically ranges from 50MB to 200MB, depending on image density and content.

Binding Type

Physical Format Implication:

N/A (Digital PDF download)

Paper Type

Physical Format Implication:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Performance

Horsepower:

Approx. 48 PS (35.3 kW) @ 6,000 rpm (subject to regional variations)

Torque:

Approx. 6.3 kgf·m (61.8 Nm) @ 5,250 rpm (subject to regional variations)

Fuel System

Induction:

Electronic Fuel Injection (EFI) with Mikuni throttle body

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Lubrication

Oil Type:

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

Oil Capacity:

Approx. 3.4 L (with oil filter change).

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc, cable-actuated

Optional

Type:

Features

Final Drive:

Chain drive

Gear Ratios:

Specific ratios detailed in manual for each gear.

Transmission Oil:

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

📐 Dimensions

Exterior

Length:

Approx. 2,265 mm (89.2 in)

Width:

Approx. 850 mm (33.5 in)

Height:

Approx. 1,405 mm (55.3 in) (adjustable seat height on some variants)

Wheelbase:

Approx. 1,500 mm (59.1 in)

Weights

Wet Weight:

Approx. 187 kg (412 lbs)

Fuel Tank Capacity:

Approx. 23 Liters (6.1 US gal)

Seat Height:

Approx. 860 mm (33.9 in) (adjustable)

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle safety is primarily based on design features and rider skill).

Active Features

Brakes:

Disc brakes front and rear. ABS was an optional feature on some later models/regions.

Lighting:

Halogen headlight, LED taillight, turn signals.

Passive Features

Chassis Design:

Strong steel-tube frame, protective fairing, handguards.

Ergonomics:

Upright riding position for rider comfort and control.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital LCD display with speedometer, tachometer, odometer, trip meters, fuel gauge, clock, and warning lights.

Driver Assistance

Optional Anti-lock Braking System (ABS) available on some models, can be serviced and diagnosed using this manual.

Connectivity

Wiring Harness:

Detailed wiring diagrams are included for diagnosing electrical systems and potential accessory installations.

Engine Management

Engine Control Unit (ECU) manages fuel injection and ignition timing, troubleshooting procedures are covered.

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km (3,700 miles) or 6 months.

Air Filter Cleaning:

Every 6,000 km (3,700 miles) or 6 months.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Brake Fluid Change:

Every 2 years or 24,000 km (15,000 miles).

Fluid Specifications

Engine Oil Spec:

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

Coolant Spec:

Permanent antifreeze coolant (ethylene glycol based) with demineralized water, typically a 50:50 mix.

Brake Fluid Spec:

DOT 4.

Known Issues

Common Problems And Fixes:

Some owners have reported occasional issues with the fuel pump under heavy use, starter motor reliability, and the stock seat comfort for very long distances. The manual will provide diagnostic steps for these and other potential issues.

Preventative Maintenance Focus:

Emphasis on regular cleaning of the fuel injection system, checking electrical connections, and proper chain maintenance.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha Motor Company is a Japanese manufacturer with a long history in motorcycles, renowned for innovation and performance across various categories.

Model Evolution

Xt Series Legacy:

The XT series has a lineage of dual-sport motorcycles, with the Ténéré nameplate historically associated with long-distance, rugged off-road capability, stemming from the Paris-Dakar rally.

Production

Manufacturing Location:

Primarily manufactured in Japan.

Generational Context:

This generation of the XT660Z Ténéré represents an evolution of the model, focusing on updated technology and refinement for modern adventure riding.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

The XT660Z Ténéré is widely regarded as a capable and durable adventure motorcycle, praised for its go-anywhere attitude and relatively simple mechanicals compared to larger displacement bikes.

Ratings

User Reviews:

Consistently receives positive user reviews for its reliability, fuel economy, and suitability for touring and light off-road use.