The Yamaha XTZ660 Tenere, produced between 1991 and 1999, is a robust dual-sport motorcycle renowned for its capability in adventure touring and off-road excursions. Built upon a strong heritage in off-road motorcycling, the XTZ660 features a 660cc single-cylinder engine, a steel semi-double cradle frame, and hydraulic disc brakes for reliable performance. Its rugged construction and comfortable ergonomics have earned it a reputation for dependability and long-distance touring prowess, making it a favored choice for riders seeking adventure. This comprehensive service repair workshop manual provides detailed information for the maintenance, repair, and troubleshooting of the Yamaha XTZ660 Tenere (chassis codes 1FN, 3YF, 4BW). It covers all major systems, including the engine, transmission, chassis, suspension, and electrical system, with step-by-step instructions, diagrams, and illustrations. The manual is designed to assist owners, independent repair shops, and motorcycle technicians in performing routine maintenance, diagnostics, and complex repairs, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Yamaha Model: XTZ660 Model Variant: Tenere Generation: 1st Generation (1FN/3YF/4BW) Production Years Covered: 1991-1999 Chassis Codes: 1FN, 3YF, 4BW 👋 Introduction Market Position Target Audience: Yamaha XTZ660 owners, independent repair shops, motorcycle technicians Competitive Analysis Value Proposition: Provides dealership-level repair and maintenance information for DIY or independent service, leading to significant cost savings. Key Features Accuracy: Vehicle-specific information, not generic. Completeness: Covers all major topics, intended to be intact and not missing parts. Ease Of Use Instructional Style: Clear, concise text with illustrations and step-by-step directions. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop, Troubleshooting Secondary Coverage: Maintenance, Diagnostics, Specifications, Wiring Diagrams Page Count Estimated Page Count: Extensive (Specific count not provided, but described as comprehensive) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, timing, lubrication, cooling, fuel system, intake, exhaust Transmission And Drivetrain: Transmission operation, disassembly, assembly, clutch, drive chain, sprockets Chassis And Suspension: Frame, front forks, rear shock absorber, steering system Electrical System: Ignition, starting system, charging system, lighting, wiring diagrams, troubleshooting Brakes: Brake system inspection, maintenance, repair (Discs and calipers implied) Bodywork And Trim: Body panel removal, installation, fairings, seating Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication, fluid checks Troubleshooting: Advanced troubleshooting for mechanical and electrical issues Repair And Rebuild: Complete engine rebuild, transmission overhaul, suspension component replacement Diagnostics: System-specific diagnostics and fault finding Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts Visual Aids Diagrams Illustrations: Step-by-step instructions, diagrams, illustrations, wiring schematics 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable pages Binding Type Binding: Digital (PDF) - Print-on-demand for individual pages Paper Type Paper Format: N/A (Digital File) Compatibility Operating Systems: All Versions of Windows AND Mac Requirements Software: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, SOHC, 5-valve Displacement: 660 cc (660cc) Performance Bore X Stroke: 100.0 mm x 84.0 mm (Typical for this generation) Compression Ratio: 8.3:1 (Typical for this generation) Horsepower Approx: Approx. 47 hp @ 6,000 rpm (Model dependent, manual provides exact) Torque Approx: Approx. 5.9 kg-m @ 5,000 rpm (Model dependent, manual provides exact) Fuel System Fuel Delivery: Carburetor (Specific models may vary, manual details exact type) Carburetor Type: Mikuni BS34 (Typical for early models) Lubrication Oil Type: Yamalube or equivalent SAE 20W-40 or 10W-30 API SG (Refer to manual for precise specification) Oil Capacity: Approx. 2.6 L (2.7 US qt) with oil filter change (Refer to manual for precise specification) 🔧 Transmission Standard Type: Constant mesh, 5-speed Optional Options: N/A Features Clutch Type: Wet, multiple-disc Gear Ratios: Detailed in manual Final Drive: Chain drive 📐 Dimensions Exterior Length: Refer to manual for exact dimensions Width: Refer to manual for exact dimensions Height: Refer to manual for exact dimensions Weights Dry Weight: Approx. 179 kg (395 lbs) (Model dependent) Wet Weight: Refer to manual for exact wet weight Fuel Tank Capacity: 20 Liters (5.3 US gal) 🛡️ Safety Features Ratings Safety Features: Disc brakes front and rear, robust chassis design for adventure touring. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Frame Construction: Steel semi-double cradle frame. 💡 Technology Features Infotainment Features: Basic instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights). No advanced infotainment systems. Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km or 6 months (Refer to manual for precise interval) Air Filter Cleaning: Every 5,000 km (Refer to manual for precise interval and cleaning procedure) Spark Plug Replacement: Every 10,000 km (Refer to manual for exact plug type and gap) Valve Clearance Check: Every 10,000 km (Refer to manual for specific clearances) Fluid Specifications Coolant Type: Yamaha's Super Coolant or equivalent ethylene glycol-based antifreeze (50% solution) (Refer to manual for precise specification) Brake Fluid Type:...