2008 Yamaha XT660Z Tenere, XT660 Service Manual (P/N 11D-F8197-E0)

This Yamaha factory service manual is for the 2008 XT660Z Ténéré, model code 11D1 (EUR). The manual identifies itself as Yamaha Motor Italia S.p.A. publication 11D-F8197-E0, First Edition, May 2008. The supplied PDF contains 399 pages. No serial-number range is stated, and the publication does not identify standard XT660 models or 2009–2012 XT660Z model codes as covered, so applicability should be confirmed from the 11D1 model code before using its specifications.

• Covers the 660 cm³ liquid-cooled, 4-stroke SOHC single-cylinder engine with dry-sump lubrication, electronic fuel injection, and a constant-mesh 5-speed transmission
• Provides exploded diagrams and job-instruction charts for removal, disassembly, inspection, assembly, and repair work across the engine, chassis, cooling, fuel injection, and electrical systems
• Lists Yamaha special tools by part number, including 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
• Includes general, engine, and chassis tightening-torque tables plus lubrication points, cable routing, electrical data, test values, and periodic maintenance intervals

Manual Content Summary

Routine service coverage goes well beyond oil and filter changes. The periodic maintenance chart is organized at 1,000, 10,000, 20,000, 30,000, and 40,000 km, with the sequence repeating from 10,000 km after 50,000 km. The manual covers valve-clearance adjustment, idle and throttle-cable adjustment, ignition timing, compression testing, engine-oil service, coolant replacement, brake bleeding, drive-chain adjustment and lubrication, steering-head adjustment, fork checks, wheel/spoke inspection, and battery testing.

For engine repair, the factory procedures cover engine removal, cylinder head service, camshaft and rocker arms, the decompression system, valves and valve seats, cylinder and piston inspection, clutch overhaul, oil-pump inspection, balancer gears, shift shaft, starter clutch and A.C. magneto, starter motor, crankcase separation, crankshaft work, and transmission inspection including the main axle, drive axle, shift forks, and shift drum. Chassis repair sections go into wheel and hub service, front and rear brake calipers and master cylinders, front-fork disassembly and assembly, steering-head service, swingarm work, chain drive, and rear-shock removal and inspection.

Fuel-injection diagnosis is a major part of the manual rather than a short component check. It covers the TBDF84/DENSO ECU, fuel pump and injector testing, throttle-position-sensor adjustment, fuel-pressure testing, ECU self-diagnosis, fail-safe behavior, diagnostic mode, fault-code troubleshooting, and sensor reference checks. A separate immobilizer chapter covers circuit diagnosis, part-replacement/key-registration requirements, and fault codes 51–56. The electrical chapter also provides system-by-system troubleshooting for ignition, starting, charging, lighting, signaling, cooling-fan control, switches, relays, sensors, and the starter motor.

Named visual 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. These are backed by circuit diagrams for ignition, starting, charging, lighting, signaling, cooling, and the immobilizer system.

Specification Highlights

The 660 cm³ engine uses a 100.0 × 84.0 mm bore and stroke with a 10.00:1 compression ratio. Cold valve clearance is specified at 0.09–0.13 mm intake and 0.16–0.20 mm exhaust. Engine-oil capacity is 2.50 L without filter replacement, 2.60 L with the filter replaced, and 2.90 L total. Radiator capacity including all routes is 1.20 L, with a 0.50 L reservoir capacity. Fuel-pump output pressure is 324 kPa (46.1 psi), and the manual specifies a 12 Ω injector resistance at 20 °C (68 °F).

Chassis specifications include 50–60 mm drive-chain slack, DOT 4 brake fluid, and 650 cm³ of 10W fork oil per front-fork leg with a 145 mm oil level. Torque data includes 90 Nm (65 ft-lb) for the clutch boss, 120 Nm (85 ft-lb) for the drive sprocket, 60 Nm (44 ft-lb) for the front axle, and 105 Nm (75 ft-lb) for the rear axle.

Several repair cautions are specific enough to matter before teardown. Because the XT660Z uses a dry-sump oil system, Yamaha calls for a staged refill and oil-pressure verification; running the engine without oil appearing at the bleed point can seize the engine. During front-fork repair, excessive force can damage the oil seal and bushing, while bottoming the inner tube can damage the oil-flow stopper. The throttle body itself is specifically marked not to be disassembled, and caustic carburetor cleaner is prohibited.

Scope is equally important: the rear-shock section covers handling, removal, inspection, installation, and disposal of the nitrogen-charged unit, but not an internal damper rebuild. 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.