Yamaha XTZ-660 Tenere (1991) Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XTZ-660 Tenere Year: 1991 Motorcycle Type: Dual-Sport / Adventure Touring 👋 Introduction Market Position Category: Adventure Touring / Dual-Sport Motorcycle Target Audience: Adventure...

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类型: Motorcycle

斯库: 320694

标签: 1991 Motorcycle Motorcycles XTZ Models XTZ-660 Tenere Yamaha

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XTZ-660 Tenere

Year:

Motorcycle Type:

Dual-Sport / Adventure Touring

👋 Introduction

Market Position

Category:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Adventure riders, long-distance tourers, off-road enthusiasts, DIY mechanics.

Competitive Analysis

Competitors Era:

Honda Transalp, Suzuki DR650, Kawasaki KLR650, BMW F650.

Key Features

Model Legacy:

Part of the iconic Tenere lineage, known for ruggedness and off-road capability.

Manual Value:

Essential resource for maintaining and repairing the XTZ-660 Tenere, often used by dealership technicians.

📋 Manual Details

Coverage Areas

Engine:

Chassis:

Electrical System:

Bodywork:

Suspension:

Brakes:

Fuel System:

Cooling System:

Exhaust System:

Wheels And Tires:

Maintenance:

Troubleshooting:

Wiring Diagrams:

Page Count

Estimated Pages:

Refer to actual document (typical for workshop manuals of this era could be 300-500+ pages)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English (assumed based on typical market)

Format

File Format:

Digital Features:

Bookmarked PDF

Compatibility

Operating Systems:

Windows XP, Vista, 7, 8, Mac OS

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Comprehensive overhaul procedures, component identification, torque specifications, timing, valve clearances.

Engine Electrical:

Ignition system, charging system, starting system, CDI unit, component testing.

Fuel System:

Carburetor (Mikuni BSR34) disassembly, cleaning, adjustment, jetting, fuel pump, fuel tank and petcock.

Transmission:

Clutch operation, gearshift mechanism, gearbox disassembly and reassembly, lubrication.

Frame And Bodywork:

Frame inspection, fairing removal and installation, seat, fuel tank, fenders, chain guard.

Suspension Front:

Telescopic fork disassembly, seal replacement, oil level and type, spring rates.

Suspension Rear:

Monoshock (Monocross) system, linkage inspection, shock absorber service, spring preload adjustment.

Brakes Front:

Hydraulic disc brake system, caliper service, master cylinder, pad replacement, fluid type and bleeding.

Brakes Rear:

Drum brake system (early models) or hydraulic disc brake system, adjustment, servicing.

Electrical Wiring:

Complete color-coded wiring diagrams for all circuits, component locations.

Lighting System:

Headlight, taillight, brake light, turn signals, instrument illumination.

Instrumentation:

Speedometer, tachometer, odometer, warning lights, diagnostic indicators.

Procedures Included

Disassembly:

Step-by-step procedures for dismantling all major components and systems.

Installation:

Detailed instructions for reassembling and installing components correctly.

Maintenance:

Routine checks, lubrication points, filter replacement, fluid changes, adjustments.

Troubleshooting:

Diagnostic flowcharts and symptom-based problem solving for various issues.

Repair:

Specific repair instructions for common failures and wear items.

Tune Up:

Procedures for engine tuning, including carburetor adjustment and ignition timing.

Cleaning And Inspection:

Guidance on proper cleaning and inspection of parts during maintenance and repair.

Technical Depth

Depth:

Comprehensive workshop level, covering full rebuilds and advanced diagnostics.

Diagnostic Procedures:

Detailed technical diagnostic procedures for identifying and resolving faults.

Illustrations

Quality:

Numerous illustrations, diagrams, and schematics

Completeness

Description:

Most Complete Workshop Manual Available

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF (standard for modern PDFs)

Print Quality

Printability:

Print specific pages or the entire manual

Binding Type

Binding:

Digital (PDF) - no physical binding

Paper Type

Paper Type:

N/A (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

659 cc (659 cubic centimeters)

Bore X Stroke:

100.0 mm x 84.0 mm (approximate)

Compression Ratio:

9.2:1 (typical)

Performance

Horsepower:

Approx. 45-47 HP at 6,000 RPM (estimated, varies by market tune)

Torque:

Approx. 56 Nm (41 lb-ft) at 5,500 RPM (estimated)

Fuel System

Carburetor:

Mikuni BSR34 CV carburetor

Fuel Type:

Unleaded gasoline

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Cooling System

Cooling Method:

Liquid-cooled

Lubrication

Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 API SE, SF, SG, SH)

Oil Capacity:

Approx. 2.6 Liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh 5-speed

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain

Features

Gear Ratios:

Specific ratios detailed within the manual.

Transmission Oil Type:

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

Transmission Oil Capacity:

Approx. 0.7 Liters

📐 Dimensions

Exterior

Length:

Approx. 2230 mm (87.8 in)

Width:

Approx. 855 mm (33.7 in)

Height:

Approx. 1445 mm (56.9 in)

Wheelbase:

Approx. 1455 mm (57.3 in)

Ground Clearance:

Approx. 245 mm (9.6 in)

Weights

Dry Weight:

Approx. 171 kg (377 lbs)

Wet Weight:

Approx. 187 kg (412 lbs) (with fluids)

Wheels And Tires

Front Tire:

90/90-21 M/C 54S

Rear Tire:

130/80-18 M/C 66S

Front Wheel Size:

21 x 1.85

Rear Wheel Size:

18 x 2.50

Fuel Capacity

Fuel Tank Capacity:

20 Liters (5.3 US gal)

Reserve Fuel:

Approx. 4 Liters (1.0 US gal)

🛡️ Safety Features

Ratings

Safety Standards:

N/A (Motorcycle safety ratings differ from automotive; manual focuses on mechanical integrity)

Active Features

Braking System:

Dual disc front, disc or drum rear (model dependent), providing reliable stopping power.

Lighting:

Adequate headlight, taillight, and turn signals for visibility.

Passive Features

Frame Construction:

Robust steel frame designed for durability and handling in varied conditions.

Ergonomics:

Designed for comfortable riding position over long distances and varied terrain.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation for the era)

Driver Assistance

Assistance Features:

N/A (No electronic rider aids typical of modern motorcycles)

Lighting Technology

Headlight Type:

Halogen bulb

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 3,000-5,000 km (1,800-3,000 miles), clean and re-oil.

Spark Plug Replacement:

Every 10,000-15,000 km (6,000-9,000 miles).

Valve Clearance Check:

Every 10,000-20,000 km (6,000-12,000 miles).

Chain Lubrication:

Every 500-1,000 km (300-600 miles) and after washing or riding in rain.

Fluid Specifications

Engine Oil:

Yamalube 4 (or equivalent SAE 10W-40 API SE, SF, SG, SH)

Fork Oil:

Genuine Yamaha Fork Oil (or equivalent SAE 10W or 15W)

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid

Coolant:

Permanent type antifreeze coolant (50% mixture with distilled water)

Known Issues

Common Wear Items:

Clutch plates, fork seals, swingarm bearings, rear shock absorber bushings can wear over time.

Electrical Gremlins:

Older wiring harnesses may develop corrosion or loose connections; thorough inspection recommended.

Carburetor Performance:

Mikuni BSR34 can be sensitive to altitude and require periodic cleaning and adjustment for optimal performance.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha has a long history of producing reliable and performance-oriented motorcycles, especially in the dual-sport and adventure categories.

Model Evolution

Tenere Lineage:

The Tenere nameplate originated with the XT500 and has since been applied to various displacement models, symbolizing adventure and endurance, inspired by the Paris-Dakar Rally.

Xtz660 Development:

The XTZ660 Tenere was introduced as a middleweight adventure bike, offering a blend of off-road capability and touring comfort, powered by Yamaha's robust 4-valve single-cylinder engine.

Production

Production Years:

The XTZ660 Tenere was produced from 1991 to 1997, with updates in subsequent years.

Manufacturing Location:

Japan (primarily)