Model Years Covered:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Product Type:
Full Service Repair Manual
Target Audience:
Professional motorcycle technicians and serious DIY enthusiasts seeking in-depth repair and maintenance knowledge for the Yamaha XTZ660.
Manual Advantage:
Provides the same level of detail as manuals used by professional technicians, ensuring accuracy and completeness for all repair tasks.
Key Selling Points:
Instant PDF download, printable, covers all years 1991-1999, extensive diagnostic and repair procedures, detailed illustrations.
Engine Systems:
Engine overhaul, carburetor tuning, fuel system, ignition system, cooling system, lubrication system
Drivetrain Systems:
Clutch, transmission, final drive (chain)
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, wheels, tires
Electrical Systems:
Ignition system, lighting, charging system, starter system, battery, wiring diagrams, troubleshooting electrical faults
Braking Systems:
Front and rear brake systems (disc brakes), hydraulic components
Bodywork And Accessories:
Body panels, seat, fuel tank, fairings, luggage systems (if applicable)
Maintenance Procedures:
Regular servicing, oil changes, filter replacements, chain lubrication and adjustment, brake fluid changes, spark plug replacement, air filter cleaning/replacement
Repair Procedures:
Engine rebuilds, transmission repairs, suspension servicing, brake caliper overhauls, carburetor cleaning and synchronization, electrical component diagnosis and replacement
Diagnostic Procedures:
Troubleshooting common faults, electrical system diagnostics, mechanical component checks
Technical Depth:
Comprehensive, from basic maintenance to full rebuilds, suitable for professional technicians and experienced DIYers
Instruction Style:
Step-by-step numbered instructions
Visual Aids:
Detailed illustrations, drawings, photos, enlarged inset views
Navigational Aids:
Numbered table of contents, bold figure numbers
Special Coverage:
Wiring diagrams integrated with troubleshooting and electrical service procedures
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 1-cylinder
Bore X Stroke:
Information typically detailed within the manual.
Compression Ratio:
Information typically detailed within the manual.
Horsepower Estimate:
Approximately 40-45 hp (varies slightly by year/region, detailed in manual).
Torque Estimate:
Approximately 50-55 Nm (varies slightly by year/region, detailed in manual).
Fuel Delivery:
Carburetor(s) (likely a single Mikuni BST or similar, specific model detailed in manual)
Fuel Type:
Unleaded gasoline
Ignition Type:
CDI (Capacitor Discharge Ignition)
Length Estimate:
Approx. 2200 mm (typical for dual-sport bikes of this era).
Width Estimate:
Approx. 850 mm (typical for dual-sport bikes of this era).
Height Estimate:
Approx. 1350 mm (typical for dual-sport bikes of this era).
Dry Weight Estimate:
Approx. 170-180 kg (typical for dual-sport bikes of this era).
Fuel Tank Capacity:
Approx. 20-23 liters (typical for adventure touring, detailed in manual).
Safety Features Overview:
Dual-disc front brakes, single rear disc brake, robust chassis construction.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Frame Construction:
Steel frame designed for durability and stability in various riding conditions.
Infotainment System:
Basic analog instrumentation including speedometer, tachometer, odometer, trip meter, and indicator lights. No advanced infotainment features.
Driver Assistance Features:
None. This era of motorcycle focuses on mechanical and electrical systems rather than electronic rider aids.
Connectivity Features:
None. Connectivity is limited to electrical system wiring.
Oil Change Interval:
Typically every 3,000-5,000 km or annually (detailed specific interval in manual).
Air Filter Cleaning:
Recommended every 5,000-10,000 km, depending on riding conditions (detailed in manual).
Spark Plug Replacement:
Typically every 10,000-20,000 km (specific plug type and interval in manual).
Engine Oil Type:
Yamalube or equivalent API SG, SF, SE category motorcycle oil, SAE 10W-40 or 20W-50 (specific viscosity recommended based on climate, detailed in manual).
Coolant Type:
Permanent type antifreeze/coolant (50% solution), Yamaha specified or equivalent (detailed in manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (specified in manual).
Transmission Oil Type:
Yamaha Gear Oil Superior or equivalent SAE 80 API GL-4 (if separate transmission oil is used, typically shared with engine oil for this model, confirmation in manual).
Common Wear Items:
Chain and sprockets, brake pads, fork seals, clutch plates (normal wear for age and use, detailed replacement procedures in manual).
Potential Electrical Issues:
Age-related wiring degradation, rectifier/regulator issues (diagnostics and solutions covered in manual).
Carburetor Tuning Challenges:
Carburetors may require periodic cleaning and synchronization due to age and fuel quality variability. Detailed procedures in manual.
Yamaha Heritage:
Yamaha Motor Company is a renowned Japanese manufacturer with a long history of producing high-quality motorcycles, known for innovation and performance across various categories, including off-road and adventure touring.
Xtz660 Lineage:
The XTZ660 represents Yamaha's entry into the mid-weight adventure-touring segment, evolving from earlier dual-sport designs with a focus on comfort and capability for longer journeys and mixed terrain riding. It shares design cues and technological lineage with other Yamaha dual-purpose motorcycles.
Production Period:
The XTZ660 was primarily produced from 1991 to 1999, covering the specified model years.
