Target Audience:
Professional technicians and DIY enthusiasts seeking in-depth repair and maintenance information for the Yamaha XTZ660.
Value Proposition:
Cost-effective solution for maintaining and repairing the XTZ660, reducing reliance on expensive dealership labor.
Manual Authenticity:
Described as original workshop manuals written by manufacturers, ensuring accuracy and completeness.
Accessibility:
Instant download provides immediate access without shipping delays or costs.
Practicality:
Printable format allows users to print specific sections, keeping the main file clean from workshop grime.
Engine Mechanical:
Engine overhaul, top-end rebuild, bottom-end rebuild, cylinder head service, piston and ring replacement, crankshaft and connecting rod service, valve train adjustments.
Fuel System:
Carburetor(s) (cleaning, rebuilding, tuning), fuel pump, fuel lines, fuel tank maintenance.
Ignition System:
Spark plug service, ignition coil testing, CDI unit diagnostics, timing adjustments.
Cooling System:
Radiator maintenance, coolant flushes, water pump service, thermostat replacement, fan operation.
Transmission And Drivetrain:
Clutch inspection and adjustment, gear shift mechanism, gearbox disassembly and assembly, final drive maintenance.
Suspension:
Front fork service (oil changes, seal replacement), rear shock absorber inspection and adjustment, linkage maintenance.
Brakes:
Brake fluid replacement, caliper service, master cylinder overhaul, brake pad replacement, disc inspection.
Electrical System:
Wiring diagrams, battery testing and maintenance, charging system (stator, regulator/rectifier), lighting circuits, starter motor, horn, instrument cluster.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance, wheel bearing replacement.
Bodywork And Trim:
Fairing removal and installation, seat maintenance, fender replacement, minor body panel repairs.
Routine Maintenance:
Periodic maintenance charts, oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks.
Repair Instructions:
Step-by-step repair procedures for all major components and systems, detailed disassembly and reassembly instructions.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification and solutions.
Overhaul Procedures:
Comprehensive instructions for engine and transmission overhauls, component rebuilding.
Wiring Diagrams:
Detailed electrical wiring diagrams for all circuits and components.
Depth Of Information:
Designed for professional technicians, with sufficient detail for experienced DIY mechanics. Covers everything from basic maintenance to full engine rebuilds.
Diagnostic Capability:
Includes troubleshooting sections and diagnostic procedures to identify and resolve issues.
Specification Data:
Contains essential technical specifications such as torque values, clearances, fluid capacities, and electrical resistance values.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled (Based on typical XTZ660 configuration)
Displacement:
660cc (approximate)
Bore X Stroke:
Specific figures not provided, but detailed in the manual.
Compression Ratio:
Specific figures not provided, but detailed in the manual.
Fuel Delivery:
Carburetor (likely a single Mikuni, specific model in manual)
Fuel Type:
Unleaded gasoline (typically 90+ octane)
Ignition System:
TCI (Transistor Controlled Ignition) or similar electronic ignition.
Oil Capacity:
Specific figures not provided, but detailed in the manual.
Recommended Oil:
Yamalube or equivalent API SG/SH/SJ classification, SAE 10W-40 or 20W-50 (verify in manual).
Oil Change Interval:
Typically every 3,000-5,000 km or annually (refer to manual for exact interval).
Valve Clearance Check:
Typically every 10,000-15,000 km or as specified in the manual.
Chain Adjustment:
As needed, typically every 500-1000 km, check for slack.
Engine Oil:
Yamalube or equivalent API SG/SH/SJ, SAE 10W-40 or 20W-50 (verify in manual).
Coolant:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water (specific type in manual).
Brake Fluid:
DOT 4 hydraulic brake fluid (verify in manual).
Fork Oil:
Yamaha fork oil 10W or equivalent (specific quantity and type in manual).
Common Wear Items:
Clutch plates, cam chain tensioner, fork seals, regulator/rectifier, exhaust system corrosion.
Potential Electrical Faults:
Issues with charging system components (stator, rectifier) can occur with age.
Yamaha Legacy:
Yamaha has a long history of producing reliable and capable motorcycles, particularly in the dual-sport and adventure categories, building on iconic models like the XT series.
Xtz660 Lineage:
The XTZ660 'Ténéré' line evolved from the XT600, aiming to offer improved touring and off-road capability. This generation (1991-1999) refined the formula with liquid cooling and updated styling.
Manufacturing Origin:
Japan (Typically for Yamaha motorcycles of this era, specific plant may vary).
