Yamaha XT660Z Tenere 2008-2012 Service Repair Factory Manual

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The XT660Z Tenere, produced from 2008 to 2012, is a rugged and reliable adventure touring motorcycle built for riders who demand capability on and off the pavement. This model embodies...

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Type: Motorcycle

Vendor:

Sku: 57990

Tags: 2008 2009 2010 2011 2012 Misc Motorcycle Motorcycles XT660Z Tenere Yamaha

Product variants

Description

The XT660Z Tenere, produced from 2008 to 2012, is a rugged and reliable adventure touring motorcycle built for riders who demand capability on and off the pavement. This model embodies a rich heritage in off-road and adventure motorcycling, continuing the legacy of the Tenere nameplate known for its desert racing origins and overland prowess. Its design emphasizes ruggedness, long-travel suspension, and genuine off-road capability, making it an ideal companion for long-distance touring and challenging exploration. The XT660Z Tenere is powered by a liquid-cooled, 4-stroke, 660cc single-cylinder engine, delivering approximately 47.5 HP and 60 Nm of torque, paired with a 5-speed constant mesh transmission and chain drive. This comprehensive Service Repair Workshop Manual provides detailed information essential for maintaining and repairing the XT660Z Tenere. It covers all major systems, including complete engine overhaul, fuel and cooling systems, transmission, chassis, suspension, brakes, wheels, tires, and the electrical system. The manual includes step-by-step repair instructions, disassembly and assembly procedures, diagnostic charts for troubleshooting common issues, and factory-level technical specifications such as torque values and clearances. Additionally, it details scheduled maintenance tasks, fluid specifications, and includes complete electrical wiring diagrams, making it an indispensable resource for owners and technicians aiming to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT660Z Tenere

Year:

2008-2012

👋 Introduction

Market Position

Segment:

Adventure Touring Motorcycle

Target Audience:

Riders seeking a reliable, go-anywhere motorcycle for long-distance touring and off-road exploration.

Competitive Analysis

Competitors:

BMW F650GS/F700GS, KTM 690 Enduro, Suzuki V-Strom 650, Honda Transalp.

Key Features

Vehicle Focus:

Ruggedness, reliability, long-travel suspension, and off-road capability.

Manual Value:

Essential resource for maintaining and repairing the XT660Z Tenere, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, including disassembly, inspection, assembly, tuning, and diagnostics for the 660cc single-cylinder engine.

Fuel System:

Detailed coverage of the fuel injection system, throttle body, injectors, fuel pump, fuel filter, and fuel tank servicing.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, and fan system inspection, maintenance, and repair procedures.

Exhaust System:

Catalytic converter, mufflers, exhaust pipes, and lambda sensor maintenance and replacement.

Transmission:

Clutch operation, gear shifting mechanism, internal transmission components inspection and repair, and gearbox oil specifications.

Chassis And Frame:

Frame inspection, swingarm pivot, steering head bearings, and suspension linkage maintenance.

Suspension Front:

Telescopic fork disassembly, inspection, seal replacement, oil change, and adjustment procedures.

Suspension Rear:

Monoshock absorber inspection, linkage lubrication, and rear spring preload adjustment.

Brakes Front:

Brake caliper service, pad replacement, disc inspection, brake fluid flush and bleed procedures.

Brakes Rear:

Rear brake caliper service, pad replacement, disc inspection, brake fluid flush and bleed procedures.

Wheels And Tires:

Wheel bearing inspection and replacement, spoke tensioning, tire pressure checks, and wheel balancing.

Electrical System:

Battery maintenance, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, and fuses.

Instrumentation And Controls:

Speedometer, tachometer, multi-function display, handlebar controls, and throttle cable adjustment.

Bodywork And Fairings:

Fairing removal and installation, seat, fuel tank cover, and other body panel servicing.

Troubleshooting:

Comprehensive diagnostic charts for common problems, including starting issues, engine performance, electrical faults, and more.

Procedures Included

Maintenance:

Scheduled maintenance tasks, including oil changes, filter replacements, spark plug service, chain lubrication, and brake inspections.

Repair:

Step-by-step repair instructions for all major components and systems, from minor adjustments to complete overhauls.

Disassembly Assembly:

Detailed procedures for taking apart and reassembling various vehicle components for inspection and repair.

Diagnostics:

Guidance on identifying and resolving mechanical and electrical issues, including symptom analysis and root cause identification.

Wiring Diagrams:

Complete electrical wiring diagrams for all circuits, including lighting, ignition, charging, and instrumentation.

Technical Depth

Depth:

Factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts.

Torque Specifications:

Precise torque values for all critical fasteners and bolt connections throughout the vehicle.

Clearances And Tolerances:

Specifications for engine component clearances, bearing tolerances, and other critical measurements.

Special Tools:

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

📊 Manual Specifications

File Format

File Type:

Searchable:

Printable:

Print Quality

Image Resolution:

High-resolution scans ensuring clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

Page Count

Estimated Pages:

Approximately 400-500 pages (typical for this type of comprehensive manual).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 1-cylinder

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC, 4 valves

Performance

Max Power:

Approx. 47.5 HP (35 kW) @ 6000 rpm (specifications may vary slightly by region)

Max Torque:

Approx. 60 Nm (44.3 lb-ft) @ 5250 rpm (specifications may vary slightly by region)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Mikuni throttle body

Fuel Type:

Unleaded gasoline, minimum 91 RON

Lubrication

Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 API SG or higher)

Ignition

Ignition System:

TCI (Transistor Controlled Ignition)

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Features

Gear Ratios:

Specific gear ratios provided in the manual for each gear.

Gearbox Oil Spec:

Yamalube 4 (or equivalent SAE 80 API GL-4)

📐 Dimensions

Exterior

Length:

Approx. 2280 mm (89.8 in)

Width:

Approx. 900 mm (35.4 in)

Height:

Approx. 1450 mm (57.1 in)

Seat Height:

Approx. 895 mm (35.2 in)

Wheelbase:

Approx. 1500 mm (59.1 in)

Weights

Dry Weight:

Approx. 183 kg (403.4 lbs)

Wet Weight:

Approx. 205 kg (452 lbs) (fully fueled)

Fuel Capacity:

23 Liters (6.1 US gal)

Dimensions

Ground Clearance:

Approx. 260 mm (10.2 in)

🛡️ Safety Features

Ratings

Safety Certification:

CE marking (for European market), applicable safety standards for motorcycle operation.

Active Features

Braking System:

Disc brakes front and rear for effective stopping power.

Lighting:

Halogen headlight and LED taillight for visibility.

Passive Features

Frame Construction:

Robust steel frame designed for durability and stability.

Ergonomics:

Upright riding position for rider comfort and control during long rides and off-road conditions.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation; no advanced infotainment system typically found on modern touring bikes.

Dash Display:

Digital multi-function display with speedometer, odometer, trip meter, fuel gauge, and clock.

Driver Assistance

ABS was an optional feature on some models and markets; manual covers systems with and without ABS.

Connectivity

Connectivity Features:

No Bluetooth or smartphone connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 6,000 km (3,700 miles).

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Brake Fluid Change:

Every 24,000 km (15,000 miles) or 2 years.

Chain Maintenance:

Lubricate and adjust chain every 1,000 km (600 miles) or after riding in wet conditions.

Fluid Specifications

Engine Oil Capacity:

2.2 L (without filter change), 2.4 L (with filter change).

Coolant Type:

Ethylene glycol-based coolant, mixture of 50% coolant and 50% distilled water.

Brake Fluid Type:

DOT 4.

Known Issues

Common Issues:

Some owners have reported issues with the starter motor solenoid, clutch slave cylinder leaks, and occasional electrical gremlins. The manual addresses troubleshooting and repair for these and other potential concerns.

📚 Vehicle History

Brand Heritage

Heritage:

Yamaha's rich history in off-road and adventure motorcycles, dating back to the original XT500.

Model Evolution

Tenere Lineage:

Continuation of the legendary Tenere nameplate, known for its desert racing origins and overland capability.

Production

Model Years Covered:

2008, 2009, 2010, 2011, 2012.

Manufacturing Location:

Primarily manufactured in Japan and/or other Yamaha global facilities.

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards are not always documented, the XT660Z Tenere is widely recognized within the adventure motorcycling community for its ruggedness, reliability, and value.