🏷️ Basic Information

Make:

Yamaha

Model:

XT660Z Ténéré

Model Code:

XT660Z

Years Covered:

2008, 2009, 2010

Chassis Codes:

10B, 20S

👋 Introduction

Segment:

Adventure Touring Motorcycle

Target Customer:

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

Key Competitors:

BMW F650GS/F800GS, KTM 690 Enduro/KTM 950/990 Adventure, Honda Transalp, Suzuki V-Strom

Versatility:

Blends on-road comfort with off-road capability, often lauded for its go-anywhere nature

Engine Character:

Single-cylinder engine known for its torquey delivery and robust performance

Fuel Capacity:

Large fuel tank, extending range for extended journeys

Suspension:

Long-travel suspension designed for absorbing rough terrain

📋 Manual Details

Manual Type:

Repair Service Manual

Language:

English

Format:

PDF Download

Primary Audience:

Professional Technicians

Estimated Page Count:

Refer to product documentation for exact count (typically 300+ pages)

📖 Manual Coverage

Engine Mechanical:

Disassembly, assembly, inspection, adjustments, timing, lubrication, cooling system

Fuel System:

Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel tank, fuel filter

Ignition System:

Ignition coils, spark plugs, ECU (Engine Control Unit) related diagnostics

Exhaust System:

Exhaust pipes, muffler, catalytic converter inspection and removal

Transmission Drivetrain:

Clutch operation, gear shifting mechanism, final drive (chain and sprockets)

Frame Suspension:

Frame inspection, front forks (USD, cartridge type), rear shock absorber, linkage (if applicable), swingarm

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, brake discs, bleeding procedures

Electrical System:

Wiring diagrams, battery, starter motor, charging system (alternator/stator), lighting, sensors, ECU diagnostics, fuses, relays

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure, tire size specifications

Bodywork Plastics:

Fairing removal and installation, fuel tank cover, seat, fenders

Routine Maintenance:

Oil change, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug replacement, valve clearance check

Troubleshooting:

Diagnostic procedures for common problems, fault code interpretation (if applicable), electrical system troubleshooting

Repair Rebuild:

Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls

Adjustments:

Throttle cable adjustment, clutch cable adjustment, idle speed adjustment, suspension pre-load and damping adjustments

Lubrication:

Grease points, lubrication schedules, recommended lubricant types and quantities

Electrical Diagnostics:

Wiring harness testing, component testing (e.g., sensors, actuators), multimeter usage

Troubleshooting Guides:

Comprehensive tables for diagnosing symptoms and identifying root causes for engine, electrical, and chassis issues.

Depth Of Coverage:

Comprehensive, covering all aspects from basic maintenance to complete engine and transmission disassembly/reassembly

Diagnostic Information:

Includes detailed troubleshooting charts and procedures, wiring diagrams for fault finding

Torque Specifications:

Detailed torque values for all critical fasteners and components

Clearances Tolerances:

Specific measurements for valve clearances, bearing clearances, piston-to-cylinder wall clearances, etc.

Special Tools:

Lists required Yamaha special tools for specific procedures, along with descriptions or illustrations where applicable.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable for easy information retrieval

Print Quality:

Designed for digital viewing, printable pages

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Accuracy Reliability:

Prepared by Yamaha Motor Company, ensuring accuracy and adherence to factory specifications. This manual is the definitive source for repair information.

⚙️ Engine Specifications

Engine Type:

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

Displacement:

660cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Lubrication System:

Wet sump

Max Power:

Approx. 48 PS (35.3 kW) @ 6,000 rpm

Max Torque:

Approx. 6.1 kgf·m (60 Nm) @ 5,250 rpm

Engine Cooling:

Liquid-cooled

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

23 Liters (approx. 6.1 US gal)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Primary Drive:

Gear

Final Drive:

Chain drive

Clutch Type:

Wet, multiple-disc

📐 Dimensions

Length:

2,245 mm (88.4 in)

Width:

870 mm (34.3 in)

Height:

1,475 mm (58.1 in)

Wheelbase:

1,500 mm (59.1 in)

Ground Clearance:

260 mm (10.2 in)

Dry Weight:

183 kg (403 lbs)

Wet Weight:

Approx. 200 kg (441 lbs) (fully fueled and ready to ride)

Front Suspension Travel:

210 mm (8.3 in)

Rear Suspension Travel:

200 mm (7.9 in)

🛡️ Safety Features

Safety Features:

Dual disc front brakes, single disc rear brake; standard ABS availability may vary by market/trim

💡 Technology Features

Instrumentation:

Digital LCD instrument cluster providing speed, RPM, fuel level, gear position, odometer, trip meters, and warning lights.

ABS:

Optional ABS (Anti-lock Braking System) available on some models/markets, providing enhanced braking control.

ECU Diagnostics:

ECU (Engine Control Unit) manages fuel injection, ignition timing, and other engine parameters, allowing for advanced diagnostics via diagnostic tools (covered in the manual).

🔧 Maintenance

Oil Change Interval:

Every 10,000 km or 12 months (refer to manual for exact details)

Valve Clearance Interval:

Every 20,000 km or 24 months

Spark Plug Replacement:

Every 20,000 km

Air Filter Maintenance:

Inspection every 10,000 km, cleaning/replacement as needed based on operating conditions

Engine Oil Type:

Yamalube (or equivalent) 10W-40 API SG or higher, JASO MA

Engine Oil Capacity:

3.4 Liters (with oil filter change)

Coolant Type:

Yamaha الأمين-based permanent type antifreeze (50% solution)

Brake Fluid Type:

DOT 4

Gearbox Oil Type:

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

Gearbox Oil Capacity:

0.70 Liters

Common Wear Items:

Clutch plates, chain and sprockets, wheel bearings, brake pads

Potential Concerns:

Occasional reports of stator failure or voltage regulator issues; some riders report minor electrical gremlins if maintenance is neglected. The single-cylinder engine's vibration can lead to loosening of fasteners if not periodically checked.

📚 Vehicle History

Yamaha Motorsports Legacy:

Yamaha has a strong heritage in motorsports, including Dakar Rally wins with the original Ténéré models

Tenere Lineage:

The XT660Z Ténéré is an evolution of the iconic Ténéré nameplate, known for its off-road prowess and long-distance capability, though the XT660Z leans more towards a modern adventure-touring role with its liquid-cooled engine and EFI.

Production Period:

The XT660Z Ténéré was produced from 2008 to 2016.

🏆 Awards & Recognition

Motorcycle Reviews:

While not typically receiving specific 'awards', the XT660Z Ténéré is frequently praised in motorcycle media for its value, off-road capability for its class, and touring range, making it a popular choice among adventure riders.