🏷️ Basic Information Identification Make: Yamaha Model: XTZ660 Model Nickname: Ténéré Product Name: Yamaha XTZ660 1991-1999 Workshop Service Repair Manual PDF Download Codes Engine Code: 3yf 👋 Introduction Market Position Category: Dual-sport / Adventure Motorcycle Design Philosophy: Built for adventure and durability, offering a balance between on-road comfort and off-road capability. Competitive Analysis Competitors: Honda Transalp, Suzuki DR650, Kawasaki KLR650 (during its era) Key Features Features: Robust single-cylinder engine, long-travel suspension, durable construction, suitable for both on-road and off-road touring Target Audience: Do-it-yourself enthusiasts and professional motorcycle mechanics. 📋 Manual Details Coverage Areas Years Covered: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Content Density: Content is highly detailed with substeps, notes, cautions, and warnings for each procedure. Manual Type Type: Workshop Service Repair Manual Scope: Comprehensive Factory Service Manual covering all aspects of maintenance, repair, and troubleshooting. Language Language: English Format Format: PDF Download Compatibility: Compatible with all PC-based Windows operating systems and Mac. Delivery Delivery Method: Instant download link provided on checkout page after payment completion. Requirements Software Requirements: Adobe PDF Reader 📖 Manual Coverage Systems Covered Covered Systems: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix Engine Rebuild: Yes, detailed procedures for disassembly, inspection, and reassembly of engine components. Electrical System: Yes, includes troubleshooting, wiring diagrams, and component testing. Frame And Bodywork: Yes, covers frame inspection, repairs, fairing removal/installation, and body panel fitting. Procedures Included Procedures: Step-by-step repair procedures, complete disassembly, troubleshooting, electrical diagnostics, maintenance, servicing Suspension Service: Yes, covers fork and rear shock maintenance, adjustments, and rebuilds. Brake System Service: Yes, includes procedures for brake fluid replacement, caliper maintenance, and pad replacement. Technical Depth Depth: Complete factory service information, suitable for do-it-yourselfers and experienced mechanics, detailed illustrations and photos, specific substeps for repair procedures Diagnostics: Includes troubleshooting guides for common issues, helping to diagnose problems efficiently. Illustrations: Includes hundreds of photos and detailed illustrations, drawings, and enlarged insets to guide repair procedures. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable without restriction, individual pages or entire manual Binding Type Binding: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 4-stroke, DOHC, 5-valve, single-cylinder Performance Displacement: 660cc Bore X Stroke: 100.0 mm x 84.0 mm Compression Ratio: 9.2:1 Horsepower Est: ~47 hp @ 6,250 rpm (Specific figure may vary slightly by year/region) Torque Est: ~57 Nm @ 5,250 rpm (Specific figure may vary slightly by year/region) Power Delivery Characteristics: Torquey and tractable, suitable for off-road traction and comfortable touring. Fuel System Carburetor: Mikuni BSR36 (single) Fuel Type: Unleaded gasoline Fuel Tank Design: Large capacity for extended touring range. Lubrication System Type: Wet sump Cooling System Type: Liquid-cooled Clutch Type: Wet, multi-plate 🔧 Transmission Standard Type: 5-speed constant mesh Features Drive Type: Chain Drive Clutch Operation: Cable-actuated 📐 Dimensions Exterior Length Est: ~2240 mm Width Est: ~875 mm Height Est: ~1330 mm Wheelbase Est: ~1470 mm Ground Clearance Est: ~220 mm Weights Dry Weight Est: ~178 kg Wet Weight Est: ~197 kg (fully fueled) Fuel Tank Capacity: 20 Liters (5.3 US gal) Payload Capacity Est: Not explicitly stated, but designed for rider and luggage. 🛡️ Safety Features Passive Features Frame Type: Steel, semi-double cradle Active Features Braking System Front: Hydraulic disc Braking System Rear: Hydraulic disc 💡 Technology Features Infotainment Features: Analog speedometer, tachometer, fuel gauge, odometer, trip meter, basic indicator lights. Driver Assistance Features: N/A (Modern electronic rider aids were not prevalent during this era) Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 6 months (Refer to manual for precise intervals and conditions) Valve Clearance Check: Every 10,000 km (Refer to manual for precise intervals and conditions) Fluid Specifications Engine Oil Type: Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, SG, SH, SJ or higher (Refer to manual for exact specification) Engine Oil Capacity: Approx. 2.5 L (with filter change) Coolant Type: High-quality ethylene glycol-based coolant, 50% solution with distilled water (Refer to manual) Brake Fluid Type: DOT 4 (Refer to manual) Fork Oil Type: Yamaha Fork Oil (or equivalent) SAE 10W (Refer to manual for specific type and quantity) Known Issues Common Problems: Stalling due to carburetor issues, wear in the decompression mechanism, regulator/rectifier failure, potential for worn swingarm bearings, exhaust header pipe cracks (depending on usage and maintenance) Performance Related Issues: Carburetor jetting can sometimes be lean from the factory, potentially requiring adjustment for optimal performance, especially at higher altitudes. 📚 Vehicle History Brand Heritage Heritage: Yamaha has a long history in motorcycle manufacturing, known for performance and innovation across various segments, including off-road and adventure. Model Evolution Evolution: The XTZ660 Ténéré succeeded...