🏷️ 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: Recommended at 10,000 - 20,000 km intervals (refer to manual for specific plug type and gap). Valve Clearance Check: Typically every 10,000 - 20,000 km (crucial for engine performance). Fluid Specifications Engine Oil: SAE 10W-40, API SE, SF or SG, or higher; JASO MA certified. Coolant: Ethylene glycol-based antifreeze coolant mixed with distilled water (50:50 ratio). Brake Fluid: DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific type). Known Issues Common Wear Items: Clutch plates, brake pads, wheel bearings, fork seals, and electrical connections can be wear items requiring periodic inspection and replacement. Carburetor Maintenance: Carburetors may require periodic cleaning and synchronization due to their mechanical nature and fuel delivery function. 📚 Vehicle History Brand Heritage Legacy: Yamaha has a long history of producing reliable and capable motorcycles, particularly in the adventure and off-road segments. Model Evolution Lineage: The XTZ660 Ténéré is part of Yamaha's established Ténéré lineage, known for its long-distance touring and off-road capability. Production Manufacturing Location: Primarily manufactured in Japan (specific assembly plants may vary) 🏆 Awards & Recognition Recognitions Reputation: The...