🏷️ Basic Information

Make:

Yamaha

Model:

XTZ 660

Year:

1991

Chassis Code:

3YF

Manual Product Code:

Yamaha XTZ 660 1991 3YF Service Repair Manual

👋 Introduction

Motorcycle Segment:

Dual-sport / Adventure motorcycle.

Target Audience:

Riders seeking a reliable, versatile motorcycle for on-road commuting and light off-road exploration.

Key Competitors Era:

Honda Transalp, Suzuki DR650, Kawasaki KLR650.

Engine Type:

Liquid-cooled, four-stroke, single-cylinder.

Design Philosophy:

Robust and reliable platform with a focus on user-friendliness and moderate off-road capability.

Unique Selling Points:

Torquey single-cylinder engine, comfortable riding position, good fuel range.

📋 Manual Details

Primary Coverage:

Service, Repair

Estimated Pages:

300-400

Type:

Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine:

Detailed disassembly, assembly, troubleshooting, diagnosis, and repair of the 3YF engine.

Fuel System:

Carburetor systems, fuel delivery, fuel tank, fuel lines, and associated components.

Ignition System:

CDI ignition, spark plugs, ignition coils, wiring, and troubleshooting.

Exhaust System:

Exhaust pipes, muffler, and catalytic converter (if applicable).

Transmission:

Gearbox disassembly, assembly, inspection, lubrication, and troubleshooting.

Clutch:

Clutch operation, adjustment, friction plates, and pressure plates.

Suspension:

Front forks (telescopic), rear shock absorber, linkages, springs, and adjustments.

Brakes:

Front and rear brake systems (disc brakes), hydraulic lines, calipers, master cylinders, pads, and bleeding procedures.

Wheels And Tires:

Wheel bearings, tire pressure, wheel removal/installation, and spoke tension (if applicable).

Steering:

Handlebars, steering head bearings, and steering linkage.

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), lighting, horn, starter motor, and instrumentation.

Frame And Bodywork:

Frame inspection, body panels, seat, fuel tank, fairings, and mounting hardware.

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, brake checks, tire checks, air filter cleaning/replacement.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults.

Engine Repair:

Top-end rebuilds, bottom-end overhauls, valve clearance adjustment, piston and cylinder inspection.

Transmission Repair:

Gear selection issues, bearing replacement, seal replacement.

Carburetor Rebuild:

Disassembly, cleaning, reassembly, and jetting adjustments.

Suspension Rebuild:

Fork seal replacement, shock absorber service, oil changes.

Brake System Service:

Pad replacement, caliper servicing, master cylinder rebuild, brake fluid bleeding.

Electrical Diagnostics:

Fault finding in charging, ignition, starting, and lighting circuits.

Wiring Diagram Interpretation:

Detailed explanation and use of electrical schematics.

Depth Of Coverage:

Comprehensive, covering from routine maintenance to complete engine and component overhauls.

Diagnostic Procedures:

Includes symptom-based troubleshooting charts and specific test procedures.

Torque Specifications:

Precise torque values for all critical fasteners and engine components.

Clearances And Tolerances:

Specifications for piston-to-cylinder wall, ring gap, bearing clearances, etc.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Print Readability:

High-resolution scans, suitable for printing and digital viewing.

Physical Binding:

N/A (Digital Format)

Physical Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

3YF

Engine Type:

Liquid-cooled, four-stroke, SOHC, parallel-twin (Correction: This is likely a single cylinder engine based on common Yamaha XTZ models of this era and engine code. Re-evaluating based on typical 660cc Yamaha singles of the era like the Ténéré). Re-confirmation: Based on the 3YF code and common Yamaha single-cylinder architecture, this is indeed a single-cylinder engine.

Displacement:

660cc (approximately 659 cm³)

Bore X Stroke:

Approx. 100.0 mm x 84.0 mm

Compression Ratio:

Approx. 9.7:1

Horsepower:

Approx. 45-48 HP @ 6000-6500 RPM (Varies by market and specific tune)

Torque:

Approx. 54-58 Nm @ 4500-5000 RPM (Varies by market and specific tune)

Carburetion:

Single Mikuni CV carburetor (e.g., Mikuni BSR36 or similar).

Fuel Type:

Unleaded gasoline

Fuel Capacity:

Approx. 16-20 Liters (depending on specific model variant/tank size)

Oil Type:

Yamalube 4S or equivalent API SG, SAE 10W-40 motorcycle oil.

Oil Capacity With Filter:

Approx. 2.6 - 2.8 Liters

🔧 Transmission

Type:

5-speed constant mesh

Type:

N/A

Clutch Type:

Wet, multiple-disc, cable-actuated

Final Drive:

Chain drive

📐 Dimensions

Length:

Approx. 2205 mm

Width:

Approx. 850 mm

Height:

Approx. 1305 mm

Wheelbase:

Approx. 1470 mm

Ground Clearance:

Approx. 230 mm

Dry Weight:

Approx. 171 kg

Wet Weight:

Approx. 186 kg (estimated)

Load Capacity:

Approx. 180-200 kg (rider + luggage)

🛡️ Safety Features

Crash Safety Ratings:

N/A (Motorcycle safety ratings typically not standardized as for cars).

Braking System:

Front: Disc brake; Rear: Disc brake.

Lighting:

Halogen headlamp, taillight, turn signals.

Frame Construction:

Steel tube frame for rigidity and durability.

💡 Technology Features

Display:

Analog speedometer and tachometer, odometer, trip meter, indicator lights.

ABS:

N/A

Usb Charging:

N/A

🔧 Maintenance

Engine Oil Change:

Every 4,000 km or 4 months.

Oil Filter Replacement:

Every 8,000 km or 8 months (or with every second oil change).

Air Filter Cleaning:

Every 4,000 km or 4 months, replace every 12,000 km.

Spark Plug Replacement:

Every 10,000 km.

Valve Clearance Check:

Every 10,000 km.

Chain Lubrication Adjustment:

Every 1,000 km or after riding in wet conditions.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant:

Yamaha-recommended permanent type antifreeze coolant (50/50 mix with distilled water).

Common Wear Items:

Clutch plates, chain and sprockets, wheel bearings, fork seals.

Engine Idling Instability:

Can occur due to carburetor wear, vacuum leaks, or dirty air filter.

Electrical Connections:

Corrosion on connectors can lead to intermittent faults.

Suspension Leaks:

Fork seals and rear shock absorber can leak over time.

📚 Vehicle History

Manufacturer:

Yamaha Motor Company, Ltd.

Established Year:

1955

Predecessor Series:

Yamaha XT series (e.g., XT600).

Introduction Year:

1989 (XTZ660 Ténéré)

Design Origin:

Developed to offer a more road-biased dual-sport option with improved comfort and performance for touring and commuting over earlier XT models.

Production Years:

1989-1999 (XTZ660 Ténéré generation).

Manufacturing Location:

Japan

🏆 Awards & Recognition

Awards And Accolades:

Generally regarded as a reliable and capable adventure touring motorcycle of its era, though specific industry awards are not widely documented.