🏷️ Basic Information

Make:

Yamaha

Model:

XT660Z Tenere

Model Variant:

XT660Z

Model Nickname:

Tenere

Years Covered:

2008, 2009

Product Name Long:

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

👋 Introduction

Category:

Adventure Touring / Dual-Sport Motorcycle

Segment Description:

The XT660Z Tenere is positioned as an accessible, reliable, and rugged adventure touring motorcycle, capable of handling both paved roads and off-road trails. It appeals to riders seeking a no-frills, durable machine for exploring.

Competitors:

BMW F650GS (older generation), Kawasaki KLR650, Honda Transalp (older generations), KTM 690 Enduro R (more off-road focused).

Design Philosophy:

Simplicity, reliability, and dual-purpose capability. Focus on accessible performance and long-distance comfort with off-road potential.

Engine Type:

Torquey, fuel-injected single-cylinder engine.

Chassis Design:

Sturdy steel frame, long-travel suspension, and high ground clearance.

📋 Manual Details

Primary Coverage:

Service, Repair, Parts Identification

Vehicle Systems:

Engine, Fuel System, Cooling System, Ignition System, Electrical System, Transmission, Chassis, Suspension, Brakes, Wheels & Tires, Bodywork, Troubleshooting

Estimated Pages:

Approximately 300-400 pages (typical for this type of manual)

Type:

Service and Repair Manual / Parts Catalog (integrated)

Language:

English (likely, based on common industry practice for global markets)

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Detailed disassembly, assembly, inspection, and repair of the 660cc single-cylinder engine, including cylinder head, piston, crankshaft, camshaft, valve train, and lubrication system.

Fuel System:

Maintenance and repair of the fuel injection system (throttle body, injectors, ECU), fuel pump, fuel filter, and fuel tank.

Cooling System:

Inspection, flushing, and repair of the radiator, coolant hoses, thermostat, and water pump.

Ignition System:

Diagnosis and repair of the CDI unit, spark plug, ignition coil, and related wiring.

Electrical System:

Wiring diagrams, component testing (starter motor, alternator, battery), lighting systems, and accessory circuits.

Transmission:

Disassembly, inspection, and reassembly of the gearbox, clutch assembly, and drive chain.

Chassis:

Frame inspection and repair, sub-frame, and mounting points.

Suspension:

Front telescopic forks (USD) and rear monoshock absorber service, including oil changes, seal replacement, and spring adjustment.

Brakes:

Front and rear brake system maintenance and repair, including disc inspection, pad replacement, caliper servicing, and hydraulic line bleeding.

Wheels Tires:

Wheel bearing inspection and replacement, spoke tensioning, tire mounting and balancing.

Bodywork:

Fairing removal and installation, seat, fuel tank, and luggage rack components.

Troubleshooting:

Diagnostic charts for common problems and their resolutions.

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid changes, coolant flushes.

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly for all major vehicle systems.

Diagnostics:

Diagnostic procedures for identifying malfunctions in engine, electrical, and fuel systems.

Assembly Disassembly:

Detailed instructions for the complete teardown and rebuild of the motorcycle and its components.

Special Tools:

Identification and usage instructions for any specialized tools required for specific procedures.

Depth:

Comprehensive: Covers everything from basic routine maintenance to advanced engine rebuilding and electrical diagnostics.

Detail Level:

High: Illustrated with clear, step-by-step instructions and detailed diagrams.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Searchability:

Searchable text (typical for well-produced PDF manuals)

Quality:

High-resolution digital reproduction, suitable for printing specific sections or the entire manual.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, four-stroke, SOHC, four-valve, single-cylinder

Displacement:

660 cc (660 cm³)

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Maximum Power:

Approximately 47.5 HP (35.4 kW) @ 6,000 rpm (varies slightly by market)

Maximum Torque:

Approximately 6.4 kg-m (62.8 Nm; 46.3 lb-ft) @ 5,250 rpm (varies slightly by market)

Power Delivery:

Strong low-to-mid range torque, suitable for off-road traction and relaxed cruising.

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

23 Liters (approx. 6.1 US gallons)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Clutch:

Wet, multiple-disc

Final Drive:

O-ring sealed chain

Gear Ratios:

Specific gear ratios would be detailed in the manual, crucial for off-road and highway performance tuning.

Lubricant Type:

Yamalube 10W-40 or equivalent motorcycle-specific engine oil with API SG or higher, JASO MA.

📐 Dimensions

Length:

Approx. 2230 mm (87.8 in)

Width:

Approx. 860 mm (33.9 in)

Height:

Approx. 1475 mm (58.1 in)

Wheelbase:

Approx. 1500 mm (59.1 in)

Ground Clearance:

Approx. 260 mm (10.2 in)

Seat Height:

Approx. 875 mm (34.4 in)

Wet Weight:

Approx. 192 kg (423.3 lbs) (fully fueled and lubricated)

Dry Weight:

Approx. 177 kg (390.2 lbs)

Front Tire:

90/90-21M/C 54S

Rear Tire:

130/80-17M/C 65S

Front Suspension Travel:

210 mm (8.3 in)

Rear Suspension Travel:

190 mm (7.5 in)

🛡️ Safety Features

Safety Classification:

N/A (Motorcycle safety is assessed through specific components and rider aids rather than crash test ratings).

Braking System:

Front: Dual 298mm discs with 2-piston calipers. Rear: 245mm disc with 1-piston caliper. (Optional ABS might be available on some market variants, manual would detail this).

Lighting:

Halogen headlight, LED taillight, turn signals.

Chassis Stability:

Robust steel frame and balanced weight distribution contribute to rider confidence.

Ergonomics:

Upright riding position, comfortable seat, and well-placed controls for reduced fatigue on long rides.

💡 Technology Features

Infotainment System:

Basic analogue/digital instrument cluster providing speed, RPM, fuel level, trip meters, and indicator lights. No advanced infotainment features.

Rider Aids:

ABS was an option on some models/markets, but not standard on all. The manual will specify if ABS is present and its operation.

Connectivity Features:

No integrated Bluetooth or smartphone connectivity. Focus is on mechanical reliability.

ECU Functionality:

Engine Control Unit (ECU) manages fuel injection, ignition timing, and potentially other engine parameters for optimal performance and emissions.

Dashboard Display:

Combination of analog tachometer and digital LCD display for speed, odometer, trip meters, fuel gauge, clock, and warning lights.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 km (3,000 miles) or annually, whichever comes first. Manual will confirm exact intervals and conditions.

Oil Filter Replacement:

Recommended with every oil change.

Air Filter Cleaning Replacement:

Regular inspection and cleaning every 5,000 km, replacement as needed. Crucial for the single-cylinder engine.

Spark Plug Replacement:

Typically every 10,000-15,000 km. Specific plug type (e.g., NGK CR9E) and gap will be in manual.

Chain Adjustment Lubrication:

Recommended every 1,000 km or after riding in wet/dusty conditions.

Valve Clearance Check:

Typically at 20,000 km or 40,000 km intervals. Crucial for engine longevity.

Engine Oil Capacity:

2.4 Liters (with oil filter change) / 2.2 Liters (without oil filter change)

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (50:50 ratio). Refer to manual for specific Yamaha coolant part number.

Brake Fluid Type:

DOT 4 (refer to manual for specific recommendations and brand considerations).

Common Wear Items:

Clutch plates, wheel bearings, chain and sprockets, fork seals, and brake pads due to dual-purpose use.

Potential Engine Quirks:

Some owners report occasional minor electrical gremlins or a tendency for the single-cylinder to vibrate at higher RPMs. Proper maintenance and torque specifications are key.

📚 Vehicle History

Yamaha Legacy:

Yamaha has a long and distinguished history in motorcycle manufacturing, particularly in off-road and dual-sport segments, dating back to the iconic XT500. The Tenere name itself evokes the challenging Paris-Dakar rally raids.

Tenere Lineage:

The XT660Z Tenere continues the lineage of Yamaha's durable adventure bikes, building upon the legacy of earlier models like the XT500, XT600 Tenere, and XTZ750 Super Tenere. It represents a modern interpretation of the 'go anywhere' spirit.

Production Period:

The XT660Z Tenere was produced from 2008 to 2016, with the 2008-2009 models representing the initial generation of this specific iteration.