🏷️ Basic Information

Make:

Yamaha

Model:

XT660Z Ténéré

Model Nickname:

Ténéré

Product Type:

Full Service Repair Manual

Generation Code:

2nd Generation (2008-2016)

Internal Model Code:

H401E

👋 Introduction

Motorcycle Segment:

Adventure Touring / Dual-Sport

Key Competitors:

BMW F650GS/F700GS, Kawasaki KLR650, Honda Transalp

Target Audience:

Riders seeking a rugged, reliable, and versatile motorcycle for long-distance touring, off-road exploration, and commuting.

Design Philosophy:

Combines the long-travel suspension and comfortable ergonomics of a dual-sport with the fuel range and touring capability of an adventure bike.

📋 Manual Details

Model Years Covered:

2008, 2009, 2010, 2011, 2012

Estimated Page Count:

450+

Manual Type:

Comprehensive Workshop / Service / Repair Manual

Language:

English

Digital Format:

PDF Download

📖 Manual Coverage

Engine Management:

Fuel injection, ignition system, ECU, sensors, actuators, emission control

Engine Mechanical:

Disassembly, inspection, reassembly, cylinder head, pistons, crankshaft, lubrication

Fuel System:

Fuel pump, injectors, fuel lines, throttle body, fuel pressure regulator

Transmission:

Clutch operation, gearbox disassembly, inspection, reassembly, lubrication

Drivetrain:

Final drive, chain, sprockets, bearing checks

Brakes:

Hydraulic system, brake calipers, master cylinders, pads, discs, bleeding procedures

Suspension:

Front forks (telescopic), rear shock absorber, linkage, adjustments, seal replacement

Electrical System:

Wiring diagrams, lighting, charging system (stator, rectifier/regulator), battery, starter, ignition, diagnostics

Cooling System:

Radiator, fan, coolant, thermostat, hoses, water pump

Exhaust System:

Muffler, catalytic converter (if applicable), headers, mounting

Chassis And Body:

Frame, swingarm, steering head bearings, body panels, fairings, seat

Wheels And Tires:

Tire replacement, wheel balancing, spoke tension (if applicable), rim maintenance

Instruments And Controls:

Speedometer, tachometer, indicators, switches, levers

Routine Maintenance:

Oil change, filter replacement, chain adjustment, lubrication points

Troubleshooting:

Diagnostic flowcharts, common fault diagnosis for electrical and mechanical issues

Engine Rebuild:

Complete engine overhaul procedures, component specifications, torque values

Suspension Repair:

Fork seal replacement, shock absorber servicing, linkage bearing maintenance

Brake Servicing:

Brake pad replacement, caliper overhaul, master cylinder servicing, bleeding

Electrical Diagnostics:

Wiring diagram interpretation, fault finding on sensors, actuators, and charging system

Fuel System Cleaning:

Throttle body cleaning, injector maintenance

Transmission Service:

Clutch adjustment and replacement, gearbox inspection

Bodywork Repair:

Fairing removal and installation, panel replacement

Depth Of Coverage:

Detailed technical procedures, specifications, and diagrams for all major systems, suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Resolution:

High-resolution, suitable for printing

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

Text Searchability:

Searchable text for quick information retrieval

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 4-stroke, SOHC, 4-valve, liquid-cooled

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves

Horsepower Peak:

Approx. 47.5 hp @ 6000 rpm

Torque Peak:

Approx. 60 Nm (44.3 lb-ft) @ 5250 rpm

Fuel Type:

Unleaded gasoline (91 RON or higher)

Oil Type:

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

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Gear Ratios:

Specific ratios available in manual (e.g., 1st: 2.563, 2nd: 1.857, 3rd: 1.429, 4th: 1.174, 5th: 1.000)

📐 Dimensions

Length:

Approx. 2250 mm (88.6 in)

Width:

Approx. 870 mm (34.3 in)

Height:

Approx. 1475 mm (58.1 in) (with windscreen)

Wheelbase:

Approx. 1500 mm (59.1 in)

Ground Clearance:

Approx. 215 mm (8.5 in)

Seat Height:

Approx. 870 mm (34.3 in)

Wet Weight:

Approx. 205 kg (452 lbs) (curb weight)

Fuel Capacity:

23 Liters (6.1 US gal)

🛡️ Safety Features

Safety Certification:

CE, EPA (region dependent)

Braking System:

Front: Dual piston caliper with 298mm disc; Rear: Single piston caliper with 245mm disc. (ABS optional on some models/markets, not standard for all 2008-2012 models.)

Lighting:

Halogen headlight, LED tail light, LED turn signals (design varies by market/year)

💡 Technology Features

Dashboard Instruments:

Analog tachometer, multi-function LCD display (speedometer, odometer, trip meters, fuel gauge, clock, indicator lights).

ABS Availability:

ABS was an optional feature on certain markets and model years within the 2008-2012 range. Manual coverage reflects both ABS and non-ABS systems where applicable.

Charging Port:

No factory-integrated USB or 12V charging port. Aftermarket options are common and can be installed with guidance from electrical system sections.

🔧 Maintenance

Engine Oil Change:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 10,000 km (6,000 miles) or 12 months.

Spark Plug Check And Replace:

Check every 10,000 km (6,000 miles), replace as needed or every 20,000 km (12,000 miles).

Air Filter Cleaning And Replacement:

Clean every 5,000 km (3,000 miles), replace every 15,000 km (9,000 miles) or as needed.

Valve Clearance Check:

Every 20,000 km (12,000 miles).

Engine Oil Capacity:

2.2 Liters (with filter change), 2.0 Liters (without filter change).

Coolant Type:

Yamaha Coolant (Blue) or equivalent ethylene glycol-based antifreeze mixed with de-ionized water (50:50 ratio).

Brake Fluid:

DOT 4

Transmission Oil Type:

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

Stator Reliability:

Some owners have reported premature stator failure, leading to charging system issues. Diagnosis and replacement are covered in the manual.

Fuel Pump Issues:

Rare instances of fuel pump issues have been noted; the manual details fuel system diagnostics.

Front Fork Seals:

Like many dual-sport bikes, front fork seals can wear over time, especially with off-road use. The manual provides seal replacement procedures.

📚 Vehicle History

Yamaha Offroad Legacy:

Yamaha's long history in Dakar Rally and off-road racing, influencing the Ténéré lineage.

Ténéré Lineage:

Successor to the XT660R, bridging the gap between the XT660R and larger Ténéré models. This generation (2nd) marked a significant update with its distinctive twin-headlight fairing and improved aerodynamics for touring.

Manufacturing Location:

Japan (Engine components, assembly varied)

Production Period For This Manual:

2008 - 2012

🏆 Awards & Recognition

Press Reviews:

Generally well-received for its ruggedness, off-road capability, and value for money in the adventure touring segment, though often noted as having a less powerful engine compared to some twins.

Reliability Perception:

Considered a reliable and robust motorcycle, particularly the engine, with the manual providing critical information for routine maintenance to ensure longevity.