Model Generation:
Second Generation (XT660Z)
Production Years Covered:
2008, 2009, 2010, 2011, 2012
Chassis Codes:
Various, often model-specific internal Yamaha codes not typically exposed in manual titles.
Segment:
Adventure Touring / Dual-Sport Motorcycle
Target Audience:
Riders seeking long-distance comfort, off-road capability, and reliability for adventure touring.
Key Competitors:
BMW F650GS/F700GS, Kawasaki KLR650, Suzuki V-Strom 650, KTM 690 Enduro R (in certain aspects).
Distinctive Traits:
Robust single-cylinder engine, long-travel suspension, large fuel tank, excellent wind protection, and a reputation for durability and go-anywhere capability.
Manual Value Proposition:
Essential resource for owners to maintain, diagnose, and repair their XT660Z Tenere, maximizing its lifespan and performance, especially in remote locations.
Primary Coverage:
Complete mechanical and electrical repair and maintenance
Specific Systems Covered:
Engine, fuel system, exhaust, transmission, clutch, suspension (front and rear), brakes (front and rear), wheels, tires, electrical system, ignition system, lighting, bodywork, frame, troubleshooting
Type:
Workshop Service Manual
Purpose:
Intended for professional motorcycle technicians and experienced DIY mechanics.
Primary Language:
English
Engine Mechanical:
Detailed disassembly, inspection, assembly, and troubleshooting of the engine, including cylinder head, valves, piston, crankshaft, connecting rods, and lubrication system.
Fuel System:
Covers fuel injection system (EFI), fuel pump, injectors, throttle body, and evaporative emission control system.
Exhaust System:
Information on exhaust pipes, mufflers, and oxygen sensors (if applicable).
Transmission Drivetrain:
Includes manual clutch operation, gearbox disassembly and assembly, gear selection mechanism, and final drive (chain and sprockets).
Suspension Steering:
Front telescopic forks (including oil change, seal replacement) and rear monoshock suspension, linkage, and steering system (headstock bearings).
Braking System:
Front and rear disc brakes, hydraulic system, brake calipers, master cylinders, brake fluid replacement, pad replacement, and bleeding procedures.
Wheels Tires:
Wheel removal, installation, bearing maintenance, and tire pressure recommendations.
Electrical System:
Comprehensive coverage of battery, charging system (stator, rectifier/regulator), starter motor, ignition system (ECU, ignition coils, spark plugs), lighting (headlight, taillight, indicators), instrumentation, and wiring diagrams.
Bodywork Frame:
Instructions for removing and installing body panels, seat, fuel tank, fairings, and frame inspections.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain lubrication and adjustment, brake fluid replacement, coolant checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, including diagnostic trouble codes (DTCs) for the EFI system.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system repairs, and bodywork restoration.
Wiring Diagrams:
Detailed electrical schematics for accurate diagnosis and repair of the electrical system.
Depth:
Comprehensive, covering everything from basic adjustments and fluid changes to complete engine and transmission disassembly/reassembly, and advanced electrical diagnostics.
Searchability:
Likely text-searchable if originally created from a digital source or scanned with OCR.
Scan Resolution:
Typically high resolution for clarity of diagrams and text, suitable for printing.
Digital Access:
Downloadable file
Digital Content:
Contains technical diagrams, schematics, part numbers, specifications, and step-by-step repair instructions.
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder
Bore X Stroke:
100.0 mm x 84.0 mm
Compression Ratio:
10.0:1
Horsepower Est:
Approx. 48 HP (35 kW) @ 6,000 rpm
Torque Est:
Approx. 60 Nm (44 lb-ft) @ 5,250 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual intake manifold
Fuel Type:
Unleaded gasoline
Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher
Oil Capacity W Filter:
3.4 Liters (3.6 US qt)
Coolant Type:
Ethylene glycol based antifreeze with water (50:50 mix)
Safety Certification:
Meets relevant national and international motorcycle safety standards.
Braking System Performance:
Dual disc front, single disc rear for effective stopping power. ABS was an optional feature on some models/markets.
Lighting:
Halogen headlight for good visibility, LED taillight.
Frame Construction:
Steel semi-double cradle frame for rigidity and durability.
Ergonomics:
Upright riding position and comfortable seating for long-distance riding, contributing to rider fatigue reduction.
Instrument Cluster:
Digital LCD instrument cluster featuring speedometer, tachometer, odometer, trip meters, fuel gauge, clock, and warning lights.
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature on select models and markets, not standard across all units.
Diagnostic Port:
Features a diagnostic port for connecting to diagnostic tools, enabling fault code reading and analysis of EFI system parameters.
ECU Functionality:
Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters for optimal performance and emissions.
Engine Oil Change:
Every 10,000 km (6,000 miles) or 12 months.
Oil Filter Replacement:
With every oil change.
Air Filter Maintenance:
Inspect every 5,000 km (3,000 miles), clean/replace as needed.
Spark Plug Check:
Inspect every 10,000 km (6,000 miles), replace if necessary.
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Brake Fluid Replacement:
Every 2 years or as needed, depending on service life indicators.
Engine Oil Grade:
SAE 10W-40, API SG or higher, JASO MA certified.
Coolant Type:
Yamalube Coolant (or equivalent) - 50% ethylene glycol and 50% deionized water.
Fork Oil Type:
Yamaha Special Fork Oil (or equivalent) SAE 10W
Fork Oil Quantity:
547 ml (18.5 US oz) per fork leg
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, brake pads.
Efi System Considerations:
While generally reliable, attention to fuel quality and filter maintenance is important for the EFI system.
Engine Characteristics:
The single-cylinder engine provides strong torque but can vibrate at higher RPMs; proper maintenance minimizes this.
Yamaha Legacy:
Yamaha's rich history in off-road and adventure motorcycling, with iconic models like the original Ténéré series.
Tenere Lineage:
The XT660Z Tenere builds on the Ténéré nameplate, which originated in the 1980s, offering a more modern interpretation of the adventure bike.
Xt660Z Features:
Introduced to provide a capable and reliable adventure bike using the proven XT660 platform, known for its torque and simplicity.
Manufacturing Location:
Primarily manufactured in Japan.
Market Availability:
Widely available in Europe, Australia, and other international markets.
Industry Acclaim:
While specific annual awards for this particular model year are not widely documented, the XT660Z Tenere is consistently praised by motorcycle publications and owners for its ruggedness, versatility, and value in the adventure touring segment.
Owner Satisfaction:
Generally high owner satisfaction due to its reliability, low running costs compared to larger adventure bikes, and capable performance.
Emissions Standards:
Compliant with Euro 3 emissions standards for its production years.
