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Yamaha XTZ660 1991-1999 Factory Service Repair Manual

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Basic Information Identification Make: Yamaha Model: XTZ660 Model Designation: Tenere Codes Chassis Code: Unknown (Specific chassis codes not detailed in product info) Introduction Market Position Target Audience: Yamaha XTZ660 owners and mechanics seeking official factory service information. Competitive Analysis Differentiation: Official factory manual, not third-party. Offers significant cost savings compared to shop labor. Key Features Convenience: Digital download, printable, searchable, no shipping costs or waiting. User Friendliness: Easy to use, detailed illustrations, diagrams, photos, and step-by-step instructions, no advanced computer skills required. Cost Savings Labor Savings: $50 - $60 per hour Manual Details Coverage Areas Covered Years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Covered Styles: All Styles Page Count Estimated Page Count: Hundreds of pages (Specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Repair Manual Authenticity: Actual Genuine Repair Service Factory Manual Language Language: English Format File Format: PDF Download Delivery Method: Download link provided after payment completion. Requirements: Adobe PDF Reader required. Manual Coverage Systems Covered Engine Top End: Covered Fuel System: Covered Cooling System: Covered Clutch: Covered Engine Lubrication System: Covered Crankshaft Transmission: Covered Wheels Tires: Covered Final Drive: Covered Brakes: Covered Suspension: Covered Steering: Covered Frame: Covered Electrical System: Covered General Information: Covered Appendix: Covered Engine Management: Engine management systems (understanding and analysis) Procedures Included Maintenance: Covered (Fundamentals of maintaining) Repair: Covered (Step-by-step repair guides) Troubleshooting: Covered (Advanced troubleshooting guide) Diagnostics: Covered (Engine fault symptoms, suspected parts testing) Wiring Diagrams: Covered (Trace and verify wiring diagrams) Engine Management Systems: Covered (Understand and analyze) Engine Removal Installation: Covered Tuning: Covered (Service, maintenance, repairs and tuning) Illustrations Diagrams Photos: All necessary illustrations, diagrams, and photos included to guide repair procedures. Repair Procedure Details: Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, enlarged insets for part examination. Common Fixes: Provides information on common fixes to empower owners and improve communication with mechanics. Mechanic Evaluation: Guidance on checking mechanic quality and what questions to ask. Preventative Tips: Common tips to prevent small problems from escalating. Technical Depth Depth: Comprehensive, step-by-step instructions to guide mechanics, covering all diagnostic and repair procedures in great detail. Knowledge Transfer: Transfers factory-trained technician knowledge to the owner for informed maintenance and repair decisions. Manual Specifications File Format Compatibility: Works under all PC based Windows operating systems and Mac. Print Quality Printability: Printable without any restriction (entirety or selected pages). Resolution: High resolution Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download, printable) Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, SOHC (Information inferred from typical XTZ660 configurations) Displacement: 660cc (Inferred from model name) Engine Layout: Single-cylinder (Inferred) Performance Horsepower: Not specified in product data, but typically around 45-48 hp for this model. Torque: Not specified in product data, but typically around 50-55 Nm for this model. Fuel System Fuel Delivery: Carburetor (Likely a Mikuni CV carburetor, specific model not detailed in product data) Transmission Standard Transmission Type: 5-speed manual transmission (Typical for this model) Features Clutch Type: Wet multi-plate clutch (Typical for this model) Dimensions Exterior Type: Dual-sport / Adventure motorcycle (Inferred from model designation and general knowledge) Weights Dry Weight: Not specified in product data, but typically around 180-190 kg. Safety Features Ratings Crash Test Results: N/A (Motorcycle safety ratings are not standardized like automobiles) Active Features Braking System: Disc brakes front and rear (Specifics like caliper type and rotor size not in product data) Technology Features Infotainment Features: N/A (This era of motorcycle typically lacks advanced infotainment systems beyond basic instrumentation). Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control expected on this model). Connectivity Features: N/A (No Bluetooth or smartphone integration typical for this era). Maintenance Service Intervals Oil Change Interval: Refer to manual for specific intervals (typically 3,000-5,000 km or annually) Spark Plug Replacement: Refer to manual for specific intervals (typically 10,000-15,000 km) Fluid Specifications Engine Oil Type: Refer to manual for specific viscosity (e.g., 10W-40 or 20W-50, JASO MA rated) Coolant Type: Refer to manual for specific type (typically ethylene glycol based antifreeze) Brake Fluid Type: Refer to manual for specific DOT rating (e.g., DOT 3 or DOT 4) Known Issues Common Problems: Potential issues may include carburetor tuning, stator failures, and general wear and tear on suspension and electrical components over time (details in manual). Maintenance Tips Preventative Maintenance: Regular checks of oil level, tire pressure, chain lubrication, and brake system are crucial for longevity. Vehicle History Brand Heritage Yamaha Motorcycles: Yamaha Motor Company has a long and successful history in motorcycle manufacturing, known for innovation and performance across various genres. Model Evolution Xtz660 Tenere: The XTZ660 Tenere was Yamaha's offering in the mid-weight adventure touring segment, known for its ruggedness and suitability for varied terrain, building on the legacy of the earlier Tenere models. Production Production Period: 1991-1999 (as per manual...
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Yamaha XTZ660 1991-1999 Factory Service Repair Manual
Basic Information
Identification
Make: Yamaha
Model: XTZ660
Model Designation: Tenere
Codes
Chassis Code: Unknown (Specific chassis codes not detailed in product info)
Introduction
Market Position
Target Audience: Yamaha XTZ660 owners and mechanics seeking official factory service information.
Competitive Analysis
Differentiation: Official factory manual, not third-party. Offers significant cost savings compared to shop labor.
Key Features
Convenience: Digital download, printable, searchable, no shipping costs or waiting.
User Friendliness: Easy to use, detailed illustrations, diagrams, photos, and step-by-step instructions, no advanced computer skills required.
Cost Savings
Labor Savings: $50 - $60 per hour
Manual Details
Coverage Areas
Covered Years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Covered Styles: All Styles
Page Count
Estimated Page Count: Hundreds of pages (Specific count not provided, but described as comprehensive)
Manual Type
Type: Factory Service Repair Manual
Authenticity: Actual Genuine Repair Service Factory Manual
Language
Language: English
Format
File Format: PDF Download
Delivery Method: Download link provided after payment completion.
Requirements: Adobe PDF Reader required.
Manual Coverage
Systems Covered
Engine Top End: Covered
Fuel System: Covered
Cooling System: Covered
Clutch: Covered
Engine Lubrication System: Covered
Crankshaft Transmission: Covered
Wheels Tires: Covered
Final Drive: Covered
Brakes: Covered
Suspension: Covered
Steering: Covered
Frame: Covered
Electrical System: Covered
General Information: Covered
Appendix: Covered
Engine Management: Engine management systems (understanding and analysis)
Procedures Included
Maintenance: Covered (Fundamentals of maintaining)
Repair: Covered (Step-by-step repair guides)
Troubleshooting: Covered (Advanced troubleshooting guide)
Diagnostics: Covered (Engine fault symptoms, suspected parts testing)
Wiring Diagrams: Covered (Trace and verify wiring diagrams)
Engine Management Systems: Covered (Understand and analyze)
Engine Removal Installation: Covered
Tuning: Covered (Service, maintenance, repairs and tuning)
Illustrations Diagrams Photos: All necessary illustrations, diagrams, and photos included to guide repair procedures.
Repair Procedure Details: Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, enlarged insets for part examination.
Common Fixes: Provides information on common fixes to empower owners and improve communication with mechanics.
Mechanic Evaluation: Guidance on checking mechanic quality and what questions to ask.
Preventative Tips: Common tips to prevent small problems from escalating.
Technical Depth
Depth: Comprehensive, step-by-step instructions to guide mechanics, covering all diagnostic and repair procedures in great detail.
Knowledge Transfer: Transfers factory-trained technician knowledge to the owner for informed maintenance and repair decisions.
Manual Specifications
File Format
Compatibility: Works under all PC based Windows operating systems and Mac.
Print Quality
Printability: Printable without any restriction (entirety or selected pages).
Resolution: High resolution
Binding Type
Binding: N/A (Digital Download)
Paper Type
Paper Type: N/A (Digital Download, printable)
Engine Specifications
Primary Engine
Engine Type: Single-cylinder, 4-stroke, SOHC (Information inferred from typical XTZ660 configurations)
Displacement: 660cc (Inferred from model name)
Engine Layout: Single-cylinder (Inferred)
Performance
Horsepower: Not specified in product data, but typically around 45-48 hp for this model.
Torque: Not specified in product data, but typically around 50-55 Nm for this model.
Fuel System
Fuel Delivery: Carburetor (Likely a Mikuni CV carburetor, specific model not detailed in product data)
Transmission
Standard
Transmission Type: 5-speed manual transmission (Typical for this model)
Features
Clutch Type: Wet multi-plate clutch (Typical for this model)
Dimensions
Exterior
Type: Dual-sport / Adventure motorcycle (Inferred from model designation and general knowledge)
Weights
Dry Weight: Not specified in product data, but typically around 180-190 kg.
Safety Features
Ratings
Crash Test Results: N/A (Motorcycle safety ratings are not standardized like automobiles)
Active Features
Braking System: Disc brakes front and rear (Specifics like caliper type and rotor size not in product data)
Technology Features
Infotainment
Features: N/A (This era of motorcycle typically lacks advanced infotainment systems beyond basic instrumentation).
Driver Assistance
Features: N/A (No electronic rider aids like ABS or traction control expected on this model).
Connectivity
Features: N/A (No Bluetooth or smartphone integration typical for this era).
Maintenance
Service Intervals
Oil Change Interval: Refer to manual for specific intervals (typically 3,000-5,000 km or annually)
Spark Plug Replacement: Refer to manual for specific intervals (typically 10,000-15,000 km)
Fluid Specifications
Engine Oil Type: Refer to manual for specific viscosity (e.g., 10W-40 or 20W-50, JASO MA rated)
Coolant Type: Refer to manual for specific type (typically ethylene glycol based antifreeze)
Brake Fluid Type: Refer to manual for specific DOT rating (e.g., DOT 3 or DOT 4)
Known Issues
Common Problems: Potential issues may include carburetor tuning, stator failures, and general wear and tear on suspension and electrical components over time (details in manual).
Maintenance Tips
Preventative Maintenance: Regular checks of oil level, tire pressure, chain lubrication, and brake system are crucial for longevity.
Vehicle History
Brand Heritage
Yamaha Motorcycles: Yamaha Motor Company has a long and successful history in motorcycle manufacturing, known for innovation and performance across various genres.
Model Evolution
Xtz660 Tenere: The XTZ660 Tenere was Yamaha's offering in the mid-weight adventure touring segment, known for its ruggedness and suitability for varied terrain, building on the legacy of the earlier Tenere models.
Production
Production Period: 1991-1999 (as per manual coverage)
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