This workshop repair service manual provides comprehensive guidance for the XTZ660 Ténéré, a dual-sport adventure motorcycle produced from 1991 to 1999. Renowned for its robust single-cylinder, liquid-cooled 660 cc engine, the Ténéré is celebrated for its versatility, capable of both long-distance touring and off-road exploration. Built upon a legacy of producing reliable and durable motorcycles, the XTZ660 Ténéré offers a blend of performance and practicality, making it a favored choice for riders seeking adventure. Its engineering quality ensures dependability, while its design emphasizes a balance between on-road comfort and off-road prowess. This detailed 412-page English-language manual is designed to assist mechanical technicians, motorcycle enthusiasts, and owners in maintaining and repairing their XTZ660 Ténéré. It covers all essential systems, including the engine, fuel system, ignition, electrical components, transmission, chassis, suspension, brakes, and bodywork. The manual provides in-depth procedures for routine maintenance, troubleshooting, complete overhauls, and part installations, along with specific information on required tools and diagnostic symbols. Its comprehensive scope and technical depth aim to empower users to perform high-quality service, ensuring the optimal performance and longevity of their Ténéré. 🏷️ Basic Information Identification Make: Yamaha Model: XTZ660 Model Nickname: Ténéré Body Style: Dual-sport / Adventure Motorcycle Codes Engine Code Identifier: XTZ660 Engine Series 👋 Introduction Market Position Target Audience: Mechanical technicians, motorcycle enthusiasts, owners seeking to perform maintenance and repairs Competitive Analysis Value Proposition: Provides professional-grade information comparable to authorized dealer service departments, enabling cost savings and quality service Key Features Guidance Symbols: Highlights important information through WARNING, CAUTION, and NOTE symbols Tool References: Identifies and illustrates recommended or required special Yamaha tools Accuracy Statement: Endeavors to ensure accuracy of information for reliable repairs 📋 Manual Details Coverage Areas Years Covered: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Total Pages: 412 Manual Type Type: Workshop Repair Service Manual Language Primary Language: English Format Delivery Method: Electronic Delivery (Email) File Type: PDF Printability: Yes 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, assembly, timing, valve adjustment, cooling system Fuel System: Carburetor tuning and overhaul, fuel pump, fuel lines, fuel tank maintenance Ignition System: Ignition timing, spark plugs, ignition coil, CDI unit testing and replacement Lubrication System: Oil pump, oil filter, oil change procedures, lubrication points Exhaust System: Exhaust pipe and muffler inspection and maintenance Electrical System: Wiring diagrams, lighting, battery, starter, charging system, switches, fuses Transmission: Gearbox disassembly, assembly, inspection, clutch operation, shift mechanism Chassis: Frame inspection, steering head bearings, swingarm and linkage maintenance Suspension: Front fork overhaul, rear shock absorber maintenance, adjustments Brakes: Front and rear brake system inspection, fluid replacement, caliper and master cylinder overhaul, pad replacement Wheels And Tires: Tire pressure, spoke tension, wheel bearing maintenance, wheel replacement Bodywork: Fairing, tank, seat, and panel removal/installation, plastics repair Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication, brake checks, tire checks, spark plug replacement Troubleshooting: Diagnostic procedures for common issues, identifying causes of poor performance Repair Procedures: Detailed step-by-step instructions for component repair and replacement Overhaul: Complete engine and transmission rebuild instructions Installation: Procedures for installing new or replacement parts Tune Ups: Carburetor synchronization, ignition timing adjustments, general performance tuning Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY enthusiasts Emphasis: Special aspects of product repair and overhaul, including proprietary components 📊 Manual Specifications File Format Type: Portable Document Format (PDF) Print Quality Resolution: High-resolution, suitable for clear printing of diagrams and text Binding Type Format: Digital Download (No physical binding) Paper Type Format: N/A (Digital File) Searchability Feature: Likely includes searchable text for quick information retrieval ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, 4-stroke, liquid-cooled Displacement: 660 cc (approx.) Performance Horsepower Approx: 48-50 HP (varies by specific model year and market regulations) Torque Approx: 58-60 Nm (varies by specific model year and market regulations) Fuel System Carburetion: Likely a single Mikuni carburetor (specific model to be detailed in manual) Fuel Type: Unleaded gasoline Cooling System Type: Liquid-cooled 🔧 Transmission Standard Type: 5-speed constant mesh Features Clutch: Wet, multi-plate Fluid Type Specification: Yamaha's recommended motorcycle-specific engine oil with JASO MA rating (e.g., SAE 10W-40) 📐 Dimensions Exterior General Type: Motorcycle dimensions vary by exact configuration but typical for dual-sport. Weights Dry Weight Approx: 180-190 kg (depending on specific year and equipment) 🛡️ Safety Features Active Features Braking System: Front disc brake, Rear disc brake Passive Features Lighting: Headlight, taillight, turn signals (as per regulations) 💡 Technology Features Infotainment Features: Basic motorcycle instrumentation: speedometer, odometer, trip meter, tachometer, coolant temperature gauge, and warning lights. Driver Assistance Features: N/A (This era of motorcycle predates modern electronic rider aids like ABS or traction control). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 - 10,000 km or annually, depending on usage (refer to manual for precise intervals). Air Filter Cleaning: Check and clean every 5,000 km, replace as needed. Spark Plug Replacement:...