Yamaha XT660Z 2008-2012 Full Service Repair Manual

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The Yamaha XT660Z Ténéré, also known as the Ténéré, is a versatile adventure touring and dual-sport motorcycle produced for the 2nd Generation from 2008 to 2016. This rugged machine is...

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类型: Motorcycle

斯库: 57677

标签: 2008 2009 2010 2011 2012 Misc Motorcycle Motorcycles XT660Z Yamaha

产品多属性

Description

The Yamaha XT660Z Ténéré, also known as the Ténéré, is a versatile adventure touring and dual-sport motorcycle produced for the 2nd Generation from 2008 to 2016. This rugged machine is engineered to excel in diverse riding conditions, from long-distance highway travel to challenging off-road exploration, making it a favored choice for riders seeking adventure. Its design philosophy blends the long-travel suspension and comfortable ergonomics of a dual-sport with the fuel range and touring capabilities of a larger adventure bike, drawing on Yamaha's rich off-road racing heritage. The 660 cc single-cylinder, liquid-cooled engine, featuring electronic fuel injection, delivers dependable performance suitable for a wide array of riding demands. This comprehensive workshop and service manual provides detailed technical procedures, specifications, and diagrams for the Yamaha XT660Z Ténéré, covering model years 2008 through 2012. With over 450 pages of English content, it serves as an indispensable resource for owners, mechanics, and technicians. The manual meticulously details routine maintenance, engine mechanicals, fuel and electrical systems, transmission, brakes, suspension, and chassis components. It also includes troubleshooting guides for common issues, diagnostic flowcharts, and specific procedures for engine rebuilds and component servicing, ensuring the reliable upkeep and repair of this capable motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT660Z Ténéré

Model Nickname:

Ténéré

Product Type:

Full Service Repair Manual

Generation

Generation Code:

2nd Generation (2008-2016)

Codes

Internal Model Code:

H401E

👋 Introduction

Market Position

Motorcycle Segment:

Adventure Touring / Dual-Sport

Competitive Analysis

Key Competitors:

BMW F650GS/F700GS, Kawasaki KLR650, Honda Transalp

Key Features

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

Coverage Areas

Model Years Covered:

2008, 2009, 2010, 2011, 2012

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Comprehensive Workshop / Service / Repair Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

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

Procedures Included

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

Technical Depth

Depth Of Coverage:

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

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Resolution:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Searchability

Text Searchability:

Searchable text for quick information retrieval

⚙️ Engine Specifications

Primary Engine

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

Performance

Horsepower Peak:

Approx. 47.5 hp @ 6000 rpm

Torque Peak:

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

Fuel System

Fuel Type:

Unleaded gasoline (91 RON or higher)

Lubrication

Oil Type:

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

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Features

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

Exterior

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)

Weights

Wet Weight:

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

Fuel Capacity:

23 Liters (6.1 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

CE, EPA (region dependent)

Active Features

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.)

Passive Features

Lighting:

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

💡 Technology Features

Infotainment

Dashboard Instruments:

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

Driver Assistance

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.

Connectivity

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

Service Intervals

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).

Fluid Specifications

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

Known Issues

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

Brand Heritage

Yamaha Offroad Legacy:

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

Model Evolution

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.

Production

Manufacturing Location:

Japan (Engine components, assembly varied)

Production Period For This Manual:

2008 - 2012

🏆 Awards & Recognition

Recognitions

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.

Ratings

Reliability Perception:

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