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Yamaha XT 660 Z TENERE 600 2008-2009 Service Repair Manual & Parts Catalogue XT660Z
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🏷️ Basic Information Identification Make: Yamaha Model: XT660Z Ténéré Model Code: XT660Z Generation: First Generation (2008-2009 model years) Engine Variant Covered: Single-cylinder, 4-stroke, liquid-cooled, SOHC, 4-valve Codes Chassis Code General:...
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类型: Motorcycle
厂商:
斯库: 244479
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XT660Z Ténéré
Model Code:
XT660Z
Generation:
First Generation (2008-2009 model years)
Engine Variant Covered:
Single-cylinder, 4-stroke, liquid-cooled, SOHC, 4-valve
Codes
Chassis Code General:
H434
Engine Code General:
1BS
👋 Introduction
Market Position
Vehicle Segment:
Adventure Touring Motorcycle
Target Audience:
Riders seeking a reliable, go-anywhere motorcycle for commuting, touring, and light off-road exploration.
Competitive Analysis
Key Competitors:
BMW F650GS, Kawasaki KLR650, Honda Transalp (in markets where available).
Market Differentiation:
Ténéré's focus on robustness, long-distance comfort, and Yamaha's reputation for reliability in the dual-sport segment.
Key Features
Motorcycle Design Philosophy:
Combines the versatility of an adventure bike with the practicality of a daily rider, emphasizing durability and ease of maintenance.
Manual Value Proposition:
Provides owners and technicians with the official, detailed information needed to maintain, troubleshoot, and repair the XT660Z Ténéré, ensuring optimal performance and longevity.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual & Parts Catalogue
Primary Coverage Years:
2008-2009
Extended Coverage Notes:
Service Manual Edition 2008 is confirmed to work perfectly for 2009 models.
Page Count
Total Pages:
> 400
Language
Language:
English (ENG)
Format
File Format:
PDF
Delivery Method:
ZIP archive
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine disassembly, assembly, inspection, and repair procedures for the 1-cylinder 660cc engine.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, and related components.
Cooling System:
Radiator, cooling fan, water pump, coolant flow, and thermostat operation.
Ignition System:
ECU, ignition coils, spark plugs, and timing.
Transmission System:
Clutch operation, gear selection, gear ratios, internal transmission components, and maintenance.
Frame And Suspension:
Frame construction, front fork (telescopic, upside-down), rear shock absorber (monoshock), linkages, bearings, and adjustments.
Wheel And Tire System:
Wheel hub, spokes, rims, tire specifications, balancing, and replacement.
Braking System:
Front and rear disc brakes, calipers, master cylinders, brake lines, fluid specifications, and bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, tail light, indicators), horn, and wiring harness.
Exhaust System:
Exhaust pipes, catalytic converter (if applicable), muffler, and mounting.
Bodywork And Fairings:
Removal, installation, and repair of all body panels, fairings, seat, and fuel tank cover.
Controls And Instruments:
Handlebars, levers, throttle control, brake controls, dashboard, indicators, and switches.
Parts Catalogue:
Comprehensive parts listings with diagrams and part numbers for all major components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, tire pressure checks, and general inspections.
Troubleshooting:
Diagnostic procedures for common problems, fault finding, and symptom-based solutions.
Disassembly And Reassembly:
Step-by-step instructions for taking apart and putting back together major vehicle systems.
Component Testing:
Procedures for testing the functionality of electrical components, sensors, and mechanical parts.
Adjustments:
Instructions for adjusting clutch, throttle cables, suspension settings, and idle speed.
Repair And Rebuild:
Detailed guidance for repairing or rebuilding major engine, transmission, and suspension components.
Torque Specifications:
Essential torque values for all critical fasteners during assembly and disassembly.
Wiring Diagrams:
Complete and detailed wiring diagrams for all electrical systems, aiding in diagnostics and repair.
Technical Depth
Depth Of Coverage:
Comprehensive: Covers everything from basic maintenance to advanced engine rebuilds and electrical system diagnostics.
Illustration Quality:
High Quality: Features hundreds of detailed illustrations, diagrams, and exploded views.
Diagnostic Capability:
Advanced: Includes diagnostic charts and troubleshooting flowcharts for systematic problem identification.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text within the PDF, assuming it's not a pure image scan.
Print Quality
Printability:
Fully Printable
Quality Descriptor:
High Quality
Binding Type
Binding Type Digital:
N/A (Digital PDF)
Digital Organization:
Bookmarked for easy navigation.
Paper Type
Paper Type Digital:
N/A (Digital PDF)
Completeness
Manual Completeness:
Genuine Factory Service Manual & Parts Catalogue, indicating completeness for the specified model years.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Cooling System:
Liquid-cooled
Valve Train:
SOHC, 4 valves
Bore X Stroke:
100.0 mm x 84.0 mm
Displacement:
660 cc
Compression Ratio:
10.0:1
Performance
Claimed Horsepower:
47.5 PS (34.9 kW) @ 6,000 rpm (approximate, may vary by market)
Claimed Torque:
6.1 kgf·m (60 N·m, 44 lb·ft) @ 5,250 rpm (approximate, may vary by market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Size:
44 mm
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
23 Liters (approximate)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 5-speed
Clutch Type:
Wet, multiple disc
Final Drive:
Chain
Features
Gear Ratios Overview:
The manual will detail the specific gear ratios for each of the 5 speeds, crucial for performance tuning and maintenance.
Clutch Maintenance:
Procedures for clutch lever free play adjustment, clutch disc wear inspection, and replacement.
📐 Dimensions
Exterior
Overall Length:
2,250 mm
Overall Width:
870 mm
Overall Height:
1,445 mm
Seat Height:
895 mm
Wheelbase:
1,490 mm
Ground Clearance:
260 mm
Weights
Wet Weight:
205 kg (approximate, with all fluids and full tank)
Dry Weight:
183 kg
Front Tire Size:
90/90-21M/C 54S
Rear Tire Size:
130/80-17M/C 65S
Wheel Bolt Pattern Front:
Spoked wheel with a single disc brake, hub details in manual.
Wheel Bolt Pattern Rear:
Spoked wheel with a single disc brake, hub details in manual.
🛡️ Safety Features
Ratings
Safety Certification General:
Typically meets regional homologation standards (e.g., Euro 3, DOT).
Active Features
Braking System Type:
Hydraulic disc brakes front and rear.
ABS Availability:
ABS was an optional feature on some models/markets.
Passive Features
Lighting System:
Halogen headlight, LED tail light, and turn signals for enhanced visibility.
Chassis Design:
Steel semi-double cradle frame designed for stability and durability.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD instrument cluster displaying speed, RPM, fuel level, odometer, trip meters, clock, and warning lights.
Driver Assistance
ABS Option:
Optional ABS system available on select models, which can be diagnosed and serviced using the manual.
Connectivity
Connectivity Features:
None in the modern sense; this is a mechanically focused adventure motorcycle.
Engine Management
Efi System:
Advanced electronic fuel injection system for optimal performance, fuel efficiency, and emissions control, detailed in the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km or 6 months (refer to manual for precise Yamaha recommendation).
Air Filter Inspection:
Recommended every 10,000 km, or more frequently under dusty conditions.
Spark Plug Replacement:
Refer to manual, typically around 20,000 km or as needed based on inspection.
Valve Clearance Check:
Typically at 20,000 km or 40,000 km intervals, depending on manufacturer specifications. The manual will detail the exact interval and procedure.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment are critical. Intervals depend on usage, but lubrication every 500-1000 km is common.
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API Service SG or higher, or JASO MA.
Engine Oil Capacity:
Approx. 2.4 Liters without filter change, 2.6 Liters with filter change (verify in manual).
Coolant Type:
Permanent type anti-freeze coolant (e.g., ethylene glycol based) with distilled water in a 50:50 mix.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch wear, chain and sprockets, front fork seals (due to off-road use), and wheel bearings.
Potential Electrical Gremlins:
While generally reliable, some owners report occasional issues with electrical connectors or the starter relay; the manual's wiring diagrams are key here.
Engine Longevity:
The 660cc single-cylinder engine is known for its durability when properly maintained. The manual will guide on how to ensure this.
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Company has a long-standing reputation for innovation, performance, and reliability in motorcycle manufacturing, dating back to the 1950s.
Model Evolution
Ténéré Lineage:
The Ténéré nameplate has a rich history in rally racing and adventure touring, originating with the XT500 and XT600 models that dominated early Paris-Dakar rallies.
Xt660Z Introduction:
The XT660Z Ténéré was reintroduced to the market in 2008 as a modern iteration of the classic adventure bike, utilizing Yamaha's then-current XT660 platform.
Production
Manufacturing Location:
Typically manufactured in Japan or at Yamaha's international assembly plants.
Model Production Years:
The XT660Z Ténéré was produced from 2008 to 2016 in various iterations and markets.
🏆 Awards & Recognition
Recognitions
Model Reputation:
The XT660Z Ténéré has earned a reputation among riders for its ruggedness, go-anywhere capability, and comfortable touring ergonomics, often praised in adventure motorcycling forums and reviews.
Brand Awards General:
Yamaha consistently receives awards for engine performance, reliability, and innovation across its motorcycle range.