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Yamaha XTZ660 1993-1996 Workshop Repair Service Manual PDF Download
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Basic Information Identification Make: Yamaha Model: XTZ660 Model Nickname: Ténéré Product Type: Workshop Repair Service Manual Codes Model Years Covered: 1993, 1994, 1995, 1996 Introduction Market Position Target Audience: Owners...
Type: Marine
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Sku: 66381
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Yamaha
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| Basic Information | |
| Identification | |
| Make: | Yamaha |
| Model: | XTZ660 |
| Model Nickname: | Ténéré |
| Product Type: | Workshop Repair Service Manual |
| Codes | |
| Model Years Covered: | 1993, 1994, 1995, 1996 |
| Introduction | |
| Market Position | |
| Target Audience: | Owners and independent mechanics seeking detailed, professional repair guidance for the Yamaha XTZ660. |
| Competitive Analysis | |
| Value Proposition: | Provides OEM-level information for self-maintenance and repair, saving on dealership labor costs and empowering owners with technical knowledge. |
| Key Features | |
| Features: | ['Authoritative diagnostic and repair procedures', 'Detailed schematics and diagrams (implied by technical depth)', 'Emphasis on safety warnings and precautions', 'Guidance on specialized tools', 'Includes instructions for proprietary Yamaha components'] |
| Manual Details | |
| Coverage Areas | |
| Primary Focus: | Mechanical technicians familiar with BRP products and general automobile practices |
| Scope: | Repair and overhaul of Yamaha XTZ660 covering special aspects of the product, including proprietary components. |
| Page Count | |
| Total Pages: | 164 |
| Manual Type | |
| Type: | Service Manual / Workshop Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Systems: | ['Engine disassembly and assembly', 'Fuel system (carburetion, fuel delivery)', 'Ignition system', 'Lubrication system', 'Exhaust system'] |
| Drivetrain Systems: | ['Transmission disassembly and assembly', 'Clutch operation and adjustment', 'Final drive (chain/sprocket maintenance)'] |
| Chassis Systems: | ['Frame inspection and repair', 'Suspension (front forks, rear shock absorber)', 'Steering system', 'Brake system (hydraulic components, pad replacement)', 'Wheels and tires'] |
| Electrical Systems: | ['Wiring diagrams', 'Lighting system', 'Instrumentation', 'Starting and charging system'] |
| Bodywork And Trim: | ['Body panel removal and installation', 'Fairings and plastic components'] |
| Procedures Included | |
| Maintenance: | ['Routine maintenance checks', 'Scheduled servicing', 'Tune-ups', 'Fluid level checks and changes'] |
| Repair And Overhaul: | ['Component removal and installation', 'Engine rebuild procedures', 'Transmission repair', 'Suspension servicing', 'Brake system repair', 'Electrical system troubleshooting'] |
| Diagnostics: | ['Troubleshooting guides', 'Fault diagnosis for various systems'] |
| Technical Depth | |
| Depth: | Comprehensive, covering routine maintenance to complete engine and transmission overhauls, with emphasis on proprietary component instructions. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Delivery: | Electronic via Email |
| Print Quality | |
| Printability: | Yes |
| Binding Type | |
| Binding: | N/A (Digital PDF) |
| Paper Type | |
| Paper: | N/A (Digital PDF) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Single-cylinder, 4-stroke |
| Engine Code: | 3YF |
| Displacement: | 660cc |
| Bore X Stroke: | 100.0 mm x 84.0 mm (typical for this engine family) |
| Cooling System: | Liquid-cooled |
| Performance | |
| Horsepower: | Approx. 47 hp @ 6,250 rpm (typical for this engine) |
| Torque: | Approx. 5.6 kgf⋅m (55 Nm; 41 lb⋅ft) @ 5,250 rpm (typical for this engine) |
| Fuel System | |
| Fuel Delivery: | Carburetor |
| Carburetor Type: | Mikuni BST40 (typical) |
| Fuel Type: | Unleaded gasoline |
| Ignition | |
| Ignition System: | CDI (Capacitor Discharge Ignition) |
| Lubrication | |
| Lubrication System: | Wet sump |
| Oil Capacity: | Approx. 2.5 - 3.0 liters (check manual for exact specification) |
| Recommended Oil Viscosity: | 10W-40 (typical, refer to manual for specific temperature ranges) |
| Transmission | |
| Standard | |
| Transmission Type: | Constant mesh, 5-speed |
| Optional | |
| Optional Transmission: | N/A |
| Features | |
| Clutch Type: | Wet, multiple-disc |
| Final Drive: | Chain drive |
| Dimensions | |
| Exterior | |
| Overall Length: | Approx. 2200 mm (typical for the model) |
| Overall Width: | Approx. 830 mm (typical for the model) |
| Overall Height: | Approx. 1330 mm (typical for the model) |
| Wheelbase: | Approx. 1470 mm (typical for the model) |
| Weights | |
| Dry Weight: | Approx. 175 kg (typical for the model) |
| Wet Weight: | Approx. 188 kg (typical for the model, with fluids) |
| Capacity | |
| Fuel Tank Capacity: | Approx. 20 liters |
| Oil Capacity: | Approx. 2.5 - 3.0 liters (engine oil) |
| Safety Features | |
| Ratings | |
| Safety Ratings: | Motorcycle safety is primarily dependent on rider skill and adherence to safety practices. No standardized crash ratings apply. |
| Active Features | |
| Active Safety Features: | ['Robust braking system (disc brakes front and rear)', 'Stable chassis design', 'Adequate lighting for visibility'] |
| Passive Features | |
| Passive Safety Features: | ['Frame integrity', 'Headlight and taillight illumination'] |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (Basic motorcycle electronics) |
| Driver Assistance | |
| Driver Assistance Features: | N/A (Rider skill is primary assistance) |
| Connectivity | |
| Connectivity Features: | N/A |
| Instrumentation | |
| Instrumentation Type: | Analog speedometer, tachometer, odometer, trip meter, engine temperature warning light. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Refer to manual (typically every 3,000-5,000 km or annually) |
| Air Filter Check Interval: | Refer to manual (often every 6,000-10,000 km) |
| Spark Plug Replacement Interval: | Refer to manual (typically every 10,000-20,000 km) |
| Valve Clearance Check Interval: | Refer to manual (crucial periodic maintenance, often 10,000-20,000 km) |
| Fluid Specifications | |
| Engine Oil Type: | API SG or higher, SAE 10W-40 recommended (verify with manual) |
| Coolant Type: | Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio recommended) |
| Brake Fluid Type: | DOT 4 (verify with manual) |
| Fork Oil Type: | Refer to manual for specific viscosity (e.g., SAE 10W) |
| Known Issues | |
| Common Wear Items: | ['Clutch plates', 'Fork seals', 'Cam chain tensioner (potential for wear/failure over time)', 'Carburetor jetting/cleaning due to age and fuel variations'] |
| Electrical Concerns: | Corrosion in connectors, aging wiring harnesses (common in older bikes). |
| Engine Performance Notes: | Proper carburetor synchronization and cleaning are vital for optimal performance. Valve adjustments are critical for maintaining compression and preventing damage. |
| Vehicle History | |
| Brand Heritage | |
| Brand Focus: | Yamaha Corporation is a renowned Japanese manufacturer of a wide range of products, including motorcycles, musical instruments, and audio equipment. Its motorcycle division is known for innovation and performance. |
| Model Evolution | |
| Model Lineage: | The XTZ660 is part of Yamaha's Ténéré line, known for its dual-sport and adventure touring capabilities. This generation represented a significant update and refinement. |
| Production | |
| Production Period: | 1993-1996 |
| Manufacturing Location: | Likely Japan or Europe (specific plant not detailed in provided information) |
| Awards & Recognition | |
| Recognitions | |
| Awards And Recognition: | Specific awards for the 1993-1996 XTZ660 are not commonly highlighted in general product descriptions. The model is recognized for its adventure touring capabilities and reliability within its segment. |