Yamaha XT660Z Tenere 2008 Service Manual (P/N 11D-F8197-E0)

This Yamaha factory service manual is for the 2008 XT660Z Ténéré, model code 11D1 (EUR). Published by Yamaha Motor Italia S.p.A. as P/N 11D-F8197-E0, it is the First Edition, May 2008. Match the model code before using its specifications.

Searchable Service Text and Bookmarked Sections

Search, navigation and diagram detail: The service text is searchable, with embedded bookmarks for chapters and major sections. Wiring-diagram labels and the color-code key are not searchable. Small wiring labels require zooming; the final color diagram is visibly softer than the chapter circuit diagrams.

The ZIP download contains one printable, 399-page PDF. This total already includes both covers, five preliminary pages, eight otherwise blank pages, the color-code key, and the final color wiring-diagram sheet.

Engine Overhaul, Chassis Repair and FI Diagnosis

The coverage highlights below summarize selected contents rather than a complete table of contents. Other topics include instrument-display functions and headlight-beam adjustment.

• Routine service: Valve-clearance and control adjustments, oil and coolant service, brake bleeding, drive-chain care, and scheduled chassis and battery checks.

• Engine repair: Step-by-step engine removal, cylinder-head service, cylinder and piston inspection, crankcase separation, and crankshaft removal and installation.

• Clutch and transmission: Wet-clutch overhaul, internal transmission inspection, gear-shaft assembly instructions, and shift-operation checks before crankcase assembly.

• Brakes and chassis: Wheel and hub service, hydraulic brake repair, front-fork disassembly and assembly, steering-head service, swingarm work, and chain-drive inspection.

• Cooling system: Radiator and cap checks, thermostat testing, and water-pump disassembly, seal and bearing replacement, inspection, and reassembly.

• Fuel injection: Fuel-pump and injector testing, throttle-position-sensor adjustment, ECU self-diagnosis, diagnostic mode, and fault-code troubleshooting.

• Electrical systems: Circuit diagrams and fault-finding for ignition, starting, charging, lighting, signaling, cooling-fan control, and the immobilizer.

Written primarily for Yamaha dealers and their qualified mechanics, this manual assumes a basic understanding of mechanics and motorcycle repair techniques.

Scheduled Maintenance and Internal Engine Work

The periodic maintenance chart has scheduled columns at 1,000, 10,000, 20,000, 30,000, and 40,000 km, alongside annual checks. From 50,000 km, the maintenance sequence repeats starting with the 10,000 km intervals.

Service procedures also cover ignition-timing checks, compression testing, steering-head adjustment, fork checks, wheel and spoke inspection, and battery testing.

Valve train and bottom end: Repair coverage extends to the camshaft and rocker arms, decompression system, valves and valve seats, oil pump, balancer gears, shift shaft, starter clutch, and A.C. magneto. Transmission inspection covers the main axle, drive axle, shift forks, and shift drum.

Dry-sump lubrication: The oil-service section specifies a staged refill and oil-pressure verification; inadequate oil circulation can seize the engine. Reference data includes oil quantities with and without filter replacement, total oil capacity, radiator and reservoir capacities, and lubrication points.

Brake Repairs and Suspension Limits

Front and rear brake sections cover caliper and master-cylinder disassembly, inspection, assembly, and installation, with DOT 4 fluid specifications. Chassis references include drive-chain slack and tightening torques for the clutch boss, drive sprocket, front axle, and rear axle.

During front-fork repair, excessive force can damage the oil seal and bushing, while bottoming the inner tube can damage the oil-flow stopper.

Rear-shock scope: The nitrogen-charged unit’s section covers handling, removal, inspection, installation, and disposal, rather than an internal damper rebuild.

FI Diagnosis and Immobilizer Requirements

For the TBDF84/DENSO ECU, fault-code tables connect reported symptoms with probable causes, sensor checks, fail-safe behavior, and reinstatement requirements. Diagnostic mode supports sensor readings and actuator checks, helping distinguish a circuit or component fault from a mechanical engine problem.

Air-induction checks cover the reed-valve assembly, air cut-off valve, and solenoid. The throttle body itself is marked not to be disassembled, and caustic carburetor cleaner is prohibited.

The immobilizer section covers circuit diagnosis, fault codes 51–56, and part-replacement/key-registration requirements. Standard-key registration requires the code re-registering key; the replacement table distinguishes ECU, immobilizer-unit, and main-switch work.

Electrical References and Workshop Tools

Component tests cover switches, relays, sensors, and the starter motor. Exploded diagrams and job-instruction charts accompany repair procedures, supported by general, engine, and chassis torque tables.

Named references include Cooling System Diagrams, Lubrication Diagrams, Cable Routing, Air Induction System Diagrams, the Fuel Injection System Wiring Diagram, and the full XT660Z 2008 Wiring Diagram.

The special-tool list identifies the FI system tester 90890-03182, fuel pressure gauge 90890-03153 with adapter 90890-03176, universal clutch holder 90890-04086, crankcase separating tool 90890-01135, and flywheel puller 90890-01362.

Follow the manual’s safety precautions for fuel pressure, hydraulic brakes, hot engine oil and coolant, electrical testing, and the pressurized rear shock before performing repair work.

A Preview of Valve, Fuel-System and Fork Specifications

Cold valve clearance is specified at 0.09–0.13 mm intake and 0.16–0.20 mm exhaust.

Fuel-system test data includes a fuel-pressure specification of 324 kPa (46.1 psi) and a fuel-injector resistance of 12 Ω at 20 °C (68 °F).

Front-fork specifications list 650 cm³ of 10W oil per leg and a 145 mm oil level, measured from the top of the inner tube with the tube fully compressed and the fork spring removed.