🏷️ Basic Information Identification Make: Yamaha Model: XTZ660 Tenere Model Code: XTZ660 Generation: First Generation Codes Engine Code: 3YF (1991-1993), 4MY (1994-1996), 5VK (1997-1999) - Denotes variations in carburetion and minor component updates 👋 Introduction Market Position Market Position: Dual-purpose adventure touring motorcycle, known for its ruggedness and long-distance capabilities in various terrains. Competitive Analysis Competitors: Honda Africa Twin (XRV650/750), Suzuki DR650, Kawasaki KLR650. Key Features Key Features: Robust single-cylinder engine, long-travel suspension, large fuel tank, comfortable ergonomics for touring, capable off-road performance. Manual Value Value Proposition: Enables owners and technicians to perform maintenance, diagnostics, and repairs to dealer-level standards, saving time and money. 📋 Manual Details Coverage Areas Applicable Years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Model Variants Covered: All XTZ660 Tenere variants produced between 1991 and 1999 Page Count Page Count: 576 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, assembly, tuning, lubrication, cooling, and diagnostics. Fuel System: Carburetor(s) (likely Mikuni BST34) settings, overhaul, cleaning, fuel tank, fuel lines, fuel pump (if applicable). Ignition System: CDI, spark plug specifications, timing, coil testing, wiring diagrams. Transmission: Gearbox disassembly, assembly, clutch operation, gear selection, lubrication, torque specifications for internal components. Electrical System: Wiring diagrams for all circuits, lighting, starting system, charging system (stator, regulator/rectifier), battery, fuses, switches, instruments. Suspension: Front fork (telescopic) servicing, seal replacement, oil levels and types, rear shock absorber adjustment and overhaul. Brakes: Front and rear brake system servicing, caliper overhaul, pad replacement, master cylinder, brake fluid specifications, bleeding procedures, rotor specifications. Bodywork: Fairing removal and installation, seat, tank, fenders, paneling, general cosmetic repairs. Exhaust System: Exhaust pipe and muffler servicing, gasket replacement, torque specifications. Cooling System: Radiator, hoses, coolant type and capacity, thermostat operation. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, spark plug maintenance, valve clearance checks. Troubleshooting: Diagnostic procedures for common and uncommon issues across all major systems, symptom-based troubleshooting guides. Disassembly Assembly: Step-by-step instructions for dismantling and reassembling major vehicle components and sub-assemblies. Tune Ups: Comprehensive tune-up procedures including carburetor synchronization, ignition timing adjustments, and emissions control (where applicable). Removal Installation: Detailed procedures for removing and installing individual parts and larger assemblies. Technical Depth Depth: Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds). Target Audience: Professional technicians and experienced DIY mechanics conversant with general automotive practices. Special Tools: Identifies and illustrates recommended and required special tools for specific procedures, often with Yamaha part numbers. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Delivery Delivery Method: Electronic via Email Delivery Speed: Fast ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, single-cylinder, liquid-cooled Displacement: 659 cc Bore X Stroke: 100.0 mm x 84.0 mm Compression Ratio: 9.2:1 (Approximate, may vary slightly by year) Performance Horsepower: Approx. 45-48 HP @ 6,000 RPM (specifications vary by market and year) Torque: Approx. 5.7 kgf-m (56 Nm) @ 5,000 RPM (specifications vary by market and year) Fuel System Carburetion: Mikuni BST34 (single slide, constant velocity, dual throttle valves) or similar carburetor setup. Fuel Type: Unleaded gasoline (minimum 87 octane recommended) Cooling System Cooling Method: Liquid-cooled with electric fan Lubrication System Oil Capacity: Approx. 2.6 Liters (with filter change) Oil Type: Yamaha recommend SAE 10W-40 API SG or SH or JASO MA certified motorcycle oil. 🔧 Transmission Standard Transmission Type: Constant mesh 5-speed Clutch Type: Wet, multiple disc, cable operated Features Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: Approx. 2,245 mm (88.4 in) Width: Approx. 850 mm (33.5 in) Height: Approx. 1,465 mm (57.7 in) Wheelbase: Approx. 1,485 mm (58.5 in) Weights Dry Weight: Approx. 183 kg (403 lbs) Wet Weight: Approx. 206 kg (454 lbs) (fully fueled) Fuel Capacity Fuel Tank Capacity: 22 Liters (5.8 US gal) Wheels Tires Front Tire: 90/90-21M/C 54S Rear Tire: 130/80-17M/C 65S Suspension Travel Front Suspension Travel: Approx. 220 mm (8.7 in) Rear Suspension Travel: Approx. 200 mm (7.9 in) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is typically assessed through specific component performance and rider error, not formal crash test ratings like cars). Active Features Active Safety: Effective braking system, stable chassis, good rider visibility. Passive Features Passive Safety: Ergonomic rider controls, protective bodywork (fairing, windscreen). 💡 Technology Features Infotainment Infotainment Systems: Basic analog instrumentation (speedometer, tachometer, fuel gauge, indicator lights). No digital infotainment. Driver Assistance Driver Assistance: None. Focus is on mechanical systems and rider control. Connectivity Connectivity: None. Mechanical linkage and electrical circuits only. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,000 miles) or 6 months, whichever comes first. Air Filter Inspection: Every 5,000 km (3,000 miles), clean or replace as needed. Spark Plug Replacement: Every 10,000 km...