1991-1999 Yamaha XTZ660 Tenere Service Manual

Technical reference spanning 1991-1999 Yamaha XTZ660 Tenere models, covering engine overhaul, cooling systems, carburetion, chassis, and electrical systems. Ref: 3YF-ME1

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Document Details

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Document Number / Seller:
24704 / Walter Anderson
File Size:
87.97 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Sep 23, 2025

Models Covered & Key Technical Specifications

Authoritative Instructional Overhaul Manual: Bike Yamaha XTZ660 Tenere manual, 1991-1999 PDF Documentation-Framework

Engine Overhaul & Cooling System Handbook | Series Volume.

  • Verified Climate Parameters: Ambient Limits are standardized to 0-40C mapping.
  • Defined Processing Speed: For optimal operation, 2500-3500 rpm defines the engine speed benchmarks.
  • Standard Component Weight: 150 kg -- signifies the total assembled weight configuration.
  • Prescribed Tension Specs: The cylinder head requires 10 Nm torque sequences.
  • Nominal Holding Capacity: Drive chain slack is calibrated to 20-45mm baseline.
  • Verified Ambient Limits: For proper function, 1.2 L coolant capacity specifies system range.

Professional Workshop Service Manual & Technical Specifications

Authoritative Instructional Overhaul Manual: Bike Yamaha XTZ660 Tenere manual, 1991-1999 PDF Documentation-Framework

Engine Overhaul & Cooling System Handbook | Series Volume.

Conceptual-Layout: 1991-1999 Yamaha XTZ660 Tenere // Engineering-Metrics: Bike / Motorcycle Logic // Conceptual-Layout: includes diagrams and specifications.

Specification Overview Table

Metric Rating Architecture
Engine Type Liquid cooled 4-stroke, SOHC Engine Displacement
Bore x Stroke 100 mm x 84 mm Dimensional Data
Compression Ratio 9.2 : 1 Performance Metrics
Fuel System Regular unleaded gasoline Fuel Delivery System
Air Filter Dry type element Air Intake System
Front Brake Dual Braking System

Maintenance hierarchies are structured into the following chapters:

  • Engine Overhaul Procedures
  • Carburetion System Adjustments
  • Electrical System Schematics
  • Chassis Component Inspections
  • Periodic Maintenance Schedules

Logically requiring proper assembly and adjustment, this manual documents procedures for engine, cooling system, and carburetion. It details various maintenance tasks, including lubrication points and coolant replacement. Diagrams illustrate cable routing and component locations. The document also provides detailed specifications for engine, chassis, and electrical systems, including general torque specifications and definitions of units. It ensures proper dynamic load distribution for critical components.

FAQ

Reference the **specified** tool requirements for engine disassembly. keyboard_arrow_down

37-piece motorcycle tool kit, including flywheel puller (P/N: YU-01304) and ignition timing light (P/N: YM-33277-A), is required for specific engine disassembly procedures.

What are the **essential** electrical values for the charging system? keyboard_arrow_down

14V 24.5A at 5,000 r/min is the nominal output for the A.C. magneto generator, ensuring proper charging system performance.

Specify the **correct** calibration settings for valve clearance. keyboard_arrow_down

0.10–0.15 mm (0.004–0.006 in) for intake and 0.15–0.20 mm (0.006–0.008 in) for exhaust are the correct cold valve clearance settings.

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Reviews (4)

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This service manual has been a lifesaver for my bike maintenance. The support team was very helpful when I had questions. Fast responses and professional service!
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I appreciate how thorough this manual is. The diagrams are very helpful. Plus, the download link arrived in my email in no time. Very satisfied!
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This manual is incredibly detailed and easy to follow. Perfect for anyone looking to maintain their XTZ660. The download process was seamless, and I received my link immediately!
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The step-by-step instructions in this manual made my repairs a breeze. The customer support was also top-notch, responding to my queries quickly. Highly recommend!