The XT660Z Tenere, produced from 2008 to 2012, is a robust adventure touring motorcycle celebrated for its blend of long-distance comfort and off-road capability. Built upon a rich heritage in dual-sport motorcycling, this second-generation model features a powerful 660cc liquid-cooled single-cylinder engine, known for its strong torque delivery and reliability. Its design emphasizes durability, with long-travel suspension, a substantial 23-liter fuel tank for extended range, and excellent wind protection, making it an ideal companion for riders tackling varied terrains and long journeys. The XT660Z Tenere is recognized for its go-anywhere versatility and dependable performance, appealing to riders who prioritize substance and capability in their adventure touring machine. This workshop service manual provides comprehensive guidance for the complete mechanical and electrical repair and maintenance of the XT660Z Tenere (2008-2012). Covering critical systems such as the engine, fuel injection, transmission, brakes, suspension, and electrical components, this manual offers detailed procedures for routine maintenance, troubleshooting, and major repairs. It is intended for professional motorcycle technicians and experienced DIY mechanics, equipping them with the technical specifications, diagnostic information, and step-by-step instructions necessary to ensure the optimal performance, longevity, and safety of the vehicle. With 397 pages of detailed content in English, this manual serves as an indispensable resource for maintaining this capable adventure motorcycle. 🏷️ Basic Information Identification Make: Yamaha Model: XT660Z Tenere Model Generation: Second Generation (XT660Z) Production Years Covered: 2008, 2009, 2010, 2011, 2012 Codes Chassis Codes: Various, often model-specific internal Yamaha codes not typically exposed in manual titles. 👋 Introduction Market Position Segment: Adventure Touring / Dual-Sport Motorcycle Target Audience: Riders seeking long-distance comfort, off-road capability, and reliability for adventure touring. Competitive Analysis Key Competitors: BMW F650GS/F700GS, Kawasaki KLR650, Suzuki V-Strom 650, KTM 690 Enduro R (in certain aspects). Key Features Distinctive Traits: Robust single-cylinder engine, long-travel suspension, large fuel tank, excellent wind protection, and a reputation for durability and go-anywhere capability. Manual Value Proposition: Essential resource for owners to maintain, diagnose, and repair their XT660Z Tenere, maximizing its lifespan and performance, especially in remote locations. 📋 Manual Details Coverage Areas Primary Coverage: Complete mechanical and electrical repair and maintenance Specific Systems Covered: Engine, fuel system, exhaust, transmission, clutch, suspension (front and rear), brakes (front and rear), wheels, tires, electrical system, ignition system, lighting, bodywork, frame, troubleshooting Page Count Total Pages: 397 Manual Type Type: Workshop Service Manual Purpose: Intended for professional motorcycle technicians and experienced DIY mechanics. Language Primary Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, assembly, and troubleshooting of the engine, including cylinder head, valves, piston, crankshaft, connecting rods, and lubrication system. Fuel System: Covers fuel injection system (EFI), fuel pump, injectors, throttle body, and evaporative emission control system. Exhaust System: Information on exhaust pipes, mufflers, and oxygen sensors (if applicable). Transmission Drivetrain: Includes manual clutch operation, gearbox disassembly and assembly, gear selection mechanism, and final drive (chain and sprockets). Suspension Steering: Front telescopic forks (including oil change, seal replacement) and rear monoshock suspension, linkage, and steering system (headstock bearings). Braking System: Front and rear disc brakes, hydraulic system, brake calipers, master cylinders, brake fluid replacement, pad replacement, and bleeding procedures. Wheels Tires: Wheel removal, installation, bearing maintenance, and tire pressure recommendations. Electrical System: Comprehensive coverage of battery, charging system (stator, rectifier/regulator), starter motor, ignition system (ECU, ignition coils, spark plugs), lighting (headlight, taillight, indicators), instrumentation, and wiring diagrams. Bodywork Frame: Instructions for removing and installing body panels, seat, fuel tank, fairings, and frame inspections. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain lubrication and adjustment, brake fluid replacement, coolant checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, including diagnostic trouble codes (DTCs) for the EFI system. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system repairs, and bodywork restoration. Wiring Diagrams: Detailed electrical schematics for accurate diagnosis and repair of the electrical system. Technical Depth Depth: Comprehensive, covering everything from basic adjustments and fluid changes to complete engine and transmission disassembly/reassembly, and advanced electrical diagnostics. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Likely text-searchable if originally created from a digital source or scanned with OCR. Print Quality Scan Resolution: Typically high resolution for clarity of diagrams and text, suitable for printing. Binding Type Digital Access: Downloadable file Paper Type Digital Content: Contains technical diagrams, schematics, part numbers, specifications, and step-by-step repair instructions. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder Displacement: 660 cc Bore X Stroke: 100.0 mm x 84.0 mm Compression Ratio: 10.0:1 Performance Horsepower Est: Approx. 48 HP (35 kW) @ 6,000 rpm Torque Est: Approx. 60 Nm (44 lb-ft) @ 5,250 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual intake manifold Fuel Type: Unleaded gasoline Lubrication Oil Type: Yamalube 4 (or equivalent) SAE 10W-40 API SG...