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Yamaha XTZ660 1991-1999 Service Repair Workshop Manual

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The Yamaha XTZ660 Tenere, produced between 1991 and 1999, is a robust dual-sport motorcycle renowned for its capability in adventure touring and off-road excursions. Built upon a strong heritage in...
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类型: Motorcycle
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斯库: 57991
Yamaha XTZ660 1991-1999 Service Repair Workshop ManualYamaha XTZ660 1991-1999 Service Repair Workshop ManualYamaha XTZ660 1991-1999 Service Repair Workshop ManualYamaha XTZ660 1991-1999 Service Repair Workshop Manual
The Yamaha XTZ660 Tenere, produced between 1991 and 1999, is a robust dual-sport motorcycle renowned for its capability in adventure touring and off-road excursions. Built upon a strong heritage in off-road motorcycling, the XTZ660 features a 660cc single-cylinder engine, a steel semi-double cradle frame, and hydraulic disc brakes for reliable performance. Its rugged construction and comfortable ergonomics have earned it a reputation for dependability and long-distance touring prowess, making it a favored choice for riders seeking adventure. This comprehensive service repair workshop manual provides detailed information for the maintenance, repair, and troubleshooting of the Yamaha XTZ660 Tenere (chassis codes 1FN, 3YF, 4BW). It covers all major systems, including the engine, transmission, chassis, suspension, and electrical system, with step-by-step instructions, diagrams, and illustrations. The manual is designed to assist owners, independent repair shops, and motorcycle technicians in performing routine maintenance, diagnostics, and complex repairs, ensuring the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XTZ660
Model Variant:
Tenere
Generation:
1st Generation (1FN/3YF/4BW)
Production Years Covered:
1991-1999
Chassis Codes:
1FN, 3YF, 4BW
👋 Introduction
Market Position
Target Audience:
Yamaha XTZ660 owners, independent repair shops, motorcycle technicians
Competitive Analysis
Value Proposition:
Provides dealership-level repair and maintenance information for DIY or independent service, leading to significant cost savings.
Key Features
Accuracy:
Vehicle-specific information, not generic.
Completeness:
Covers all major topics, intended to be intact and not missing parts.
Ease Of Use
Instructional Style:
Clear, concise text with illustrations and step-by-step directions.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop, Troubleshooting
Secondary Coverage:
Maintenance, Diagnostics, Specifications, Wiring Diagrams
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but described as comprehensive)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, timing, lubrication, cooling, fuel system, intake, exhaust
Transmission And Drivetrain:
Transmission operation, disassembly, assembly, clutch, drive chain, sprockets
Chassis And Suspension:
Frame, front forks, rear shock absorber, steering system
Electrical System:
Ignition, starting system, charging system, lighting, wiring diagrams, troubleshooting
Brakes:
Brake system inspection, maintenance, repair (Discs and calipers implied)
Bodywork And Trim:
Body panel removal, installation, fairings, seating
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, fluid checks
Troubleshooting:
Advanced troubleshooting for mechanical and electrical issues
Repair And Rebuild:
Complete engine rebuild, transmission overhaul, suspension component replacement
Diagnostics:
System-specific diagnostics and fault finding
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts
Visual Aids
Diagrams Illustrations:
Step-by-step instructions, diagrams, illustrations, wiring schematics
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable pages
Binding Type
Binding:
Digital (PDF) - Print-on-demand for individual pages
Paper Type
Paper Format:
N/A (Digital File)
Compatibility
Operating Systems:
All Versions of Windows AND Mac
Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, SOHC, 5-valve
Displacement:
660 cc (660cc)
Performance
Bore X Stroke:
100.0 mm x 84.0 mm (Typical for this generation)
Compression Ratio:
8.3:1 (Typical for this generation)
Horsepower Approx:
Approx. 47 hp @ 6,000 rpm (Model dependent, manual provides exact)
Torque Approx:
Approx. 5.9 kg-m @ 5,000 rpm (Model dependent, manual provides exact)
Fuel System
Fuel Delivery:
Carburetor (Specific models may vary, manual details exact type)
Carburetor Type:
Mikuni BS34 (Typical for early models)
Lubrication
Oil Type:
Yamalube or equivalent SAE 20W-40 or 10W-30 API SG (Refer to manual for precise specification)
Oil Capacity:
Approx. 2.6 L (2.7 US qt) with oil filter change (Refer to manual for precise specification)
🔧 Transmission
Standard
Type:
Constant mesh, 5-speed
Optional
Options:
N/A
Features
Clutch Type:
Wet, multiple-disc
Gear Ratios:
Detailed in manual
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Refer to manual for exact dimensions
Width:
Refer to manual for exact dimensions
Height:
Refer to manual for exact dimensions
Weights
Dry Weight:
Approx. 179 kg (395 lbs) (Model dependent)
Wet Weight:
Refer to manual for exact wet weight
Fuel Tank Capacity:
20 Liters (5.3 US gal)
🛡️ Safety Features
Ratings
Safety Features:
Disc brakes front and rear, robust chassis design for adventure touring.
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Passive Features
Frame Construction:
Steel semi-double cradle frame.
💡 Technology Features
Infotainment
Features:
Basic instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights). No advanced infotainment systems.
Driver Assistance
Features:
N/A
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km or 6 months (Refer to manual for precise interval)
Air Filter Cleaning:
Every 5,000 km (Refer to manual for precise interval and cleaning procedure)
Spark Plug Replacement:
Every 10,000 km (Refer to manual for exact plug type and gap)
Valve Clearance Check:
Every 10,000 km (Refer to manual for specific clearances)
Fluid Specifications
Coolant Type:
Yamaha's Super Coolant or equivalent ethylene glycol-based antifreeze (50% solution) (Refer to manual for precise specification)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Drive chain and sprockets, clutch plates, fork seals, wheel bearings.
Engine Specific Notes:
Some models may experience cam chain tensioner wear; the manual will detail checks and replacement.
📚 Vehicle History
Brand Heritage
Yamaha Offroad:
Yamaha has a long and successful history in off-road and dual-sport motorcycles.
Model Evolution
Xtz Lineage:
The XTZ660 'Tenere' followed earlier dual-sport models, aiming to provide a more comfortable and capable long-distance adventure touring platform with its larger engine and improved ergonomics.
Production
Manufacturing Location:
Likely manufactured in Japan and/or Europe.
🏆 Awards & Recognition
Recognitions
Model Reputation:
Praised for its ruggedness, reliability, and long-distance touring capability, establishing a strong following among adventure riders.
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