Yamaha XTZ660 1991-1999 Workshop Repair Service Manual

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Type: Motorcycle

Vendor:

Sku: 66380

Tags: 1991 1992 1993 1994 1995 1996 1997 1998 1999 Marine Motorcycle Sterndrive XTZ660 Yamaha

Product variants

Description

This workshop repair service manual provides comprehensive guidance for the XTZ660 Ténéré, a dual-sport adventure motorcycle produced from 1991 to 1999. Renowned for its robust single-cylinder, liquid-cooled 660 cc engine, the Ténéré is celebrated for its versatility, capable of both long-distance touring and off-road exploration. Built upon a legacy of producing reliable and durable motorcycles, the XTZ660 Ténéré offers a blend of performance and practicality, making it a favored choice for riders seeking adventure. Its engineering quality ensures dependability, while its design emphasizes a balance between on-road comfort and off-road prowess. This detailed 412-page English-language manual is designed to assist mechanical technicians, motorcycle enthusiasts, and owners in maintaining and repairing their XTZ660 Ténéré. It covers all essential systems, including the engine, fuel system, ignition, electrical components, transmission, chassis, suspension, brakes, and bodywork. The manual provides in-depth procedures for routine maintenance, troubleshooting, complete overhauls, and part installations, along with specific information on required tools and diagnostic symbols. Its comprehensive scope and technical depth aim to empower users to perform high-quality service, ensuring the optimal performance and longevity of their Ténéré.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XTZ660

Model Nickname:

Ténéré

Body Style:

Dual-sport / Adventure Motorcycle

Codes

Engine Code Identifier:

XTZ660 Engine Series

👋 Introduction

Market Position

Target Audience:

Mechanical technicians, motorcycle enthusiasts, owners seeking to perform maintenance and repairs

Competitive Analysis

Value Proposition:

Provides professional-grade information comparable to authorized dealer service departments, enabling cost savings and quality service

Key Features

Guidance Symbols:

Highlights important information through WARNING, CAUTION, and NOTE symbols

Tool References:

Identifies and illustrates recommended or required special Yamaha tools

Accuracy Statement:

Endeavors to ensure accuracy of information for reliable repairs

📋 Manual Details

Coverage Areas

Years Covered:

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Page Count

Total Pages:

Manual Type

Type:

Workshop Repair Service Manual

Language

Primary Language:

English

Format

Delivery Method:

Electronic Delivery (Email)

File Type:

Printability:

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, disassembly, assembly, timing, valve adjustment, cooling system

Fuel System:

Carburetor tuning and overhaul, fuel pump, fuel lines, fuel tank maintenance

Ignition System:

Ignition timing, spark plugs, ignition coil, CDI unit testing and replacement

Lubrication System:

Oil pump, oil filter, oil change procedures, lubrication points

Exhaust System:

Exhaust pipe and muffler inspection and maintenance

Electrical System:

Wiring diagrams, lighting, battery, starter, charging system, switches, fuses

Transmission:

Gearbox disassembly, assembly, inspection, clutch operation, shift mechanism

Chassis:

Frame inspection, steering head bearings, swingarm and linkage maintenance

Suspension:

Front fork overhaul, rear shock absorber maintenance, adjustments

Brakes:

Front and rear brake system inspection, fluid replacement, caliper and master cylinder overhaul, pad replacement

Wheels And Tires:

Tire pressure, spoke tension, wheel bearing maintenance, wheel replacement

Bodywork:

Fairing, tank, seat, and panel removal/installation, plastics repair

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication, brake checks, tire checks, spark plug replacement

Troubleshooting:

Diagnostic procedures for common issues, identifying causes of poor performance

Repair Procedures:

Detailed step-by-step instructions for component repair and replacement

Overhaul:

Complete engine and transmission rebuild instructions

Installation:

Procedures for installing new or replacement parts

Tune Ups:

Carburetor synchronization, ignition timing adjustments, general performance tuning

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY enthusiasts

Emphasis:

Special aspects of product repair and overhaul, including proprietary components

📊 Manual Specifications

File Format

Type:

Portable Document Format (PDF)

Print Quality

Resolution:

High-resolution, suitable for clear printing of diagrams and text

Binding Type

Format:

Digital Download (No physical binding)

Paper Type

Format:

N/A (Digital File)

Searchability

Feature:

Likely includes searchable text for quick information retrieval

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, 4-stroke, liquid-cooled

Displacement:

660 cc (approx.)

Performance

Horsepower Approx:

48-50 HP (varies by specific model year and market regulations)

Torque Approx:

58-60 Nm (varies by specific model year and market regulations)

Fuel System

Carburetion:

Likely a single Mikuni carburetor (specific model to be detailed in manual)

Fuel Type:

Unleaded gasoline

Cooling System

Type:

Liquid-cooled

🔧 Transmission

Standard

Type:

5-speed constant mesh

Features

Clutch:

Wet, multi-plate

Fluid Type

Specification:

Yamaha's recommended motorcycle-specific engine oil with JASO MA rating (e.g., SAE 10W-40)

📐 Dimensions

Exterior

General Type:

Motorcycle dimensions vary by exact configuration but typical for dual-sport.

Weights

Dry Weight Approx:

180-190 kg (depending on specific year and equipment)

🛡️ Safety Features

Active Features

Braking System:

Front disc brake, Rear disc brake

Passive Features

Lighting:

Headlight, taillight, turn signals (as per regulations)

💡 Technology Features

Infotainment

Features:

Basic motorcycle instrumentation: speedometer, odometer, trip meter, tachometer, coolant temperature gauge, and warning lights.

Driver Assistance

Features:

N/A (This era of motorcycle predates modern electronic rider aids like ABS or traction control).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 10,000 km or annually, depending on usage (refer to manual for precise intervals).

Air Filter Cleaning:

Check and clean every 5,000 km, replace as needed.

Spark Plug Replacement:

Recommended at 10,000 - 20,000 km intervals (refer to manual for specific plug type and gap).

Valve Clearance Check:

Typically every 10,000 - 20,000 km (crucial for engine performance).

Fluid Specifications

Engine Oil:

SAE 10W-40, API SE, SF or SG, or higher; JASO MA certified.

Coolant:

Ethylene glycol-based antifreeze coolant mixed with distilled water (50:50 ratio).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific type).

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, and electrical connections can be wear items requiring periodic inspection and replacement.

Carburetor Maintenance:

Carburetors may require periodic cleaning and synchronization due to their mechanical nature and fuel delivery function.

📚 Vehicle History

Brand Heritage

Legacy:

Yamaha has a long history of producing reliable and capable motorcycles, particularly in the adventure and off-road segments.

Model Evolution

Lineage:

The XTZ660 Ténéré is part of Yamaha's established Ténéré lineage, known for its long-distance touring and off-road capability.

Production

Manufacturing Location:

Primarily manufactured in Japan (specific assembly plants may vary)

🏆 Awards & Recognition

Recognitions

Reputation:

The XTZ660 Ténéré is generally regarded as a robust and reliable adventure touring motorcycle, appreciated for its versatility and durability.