2008 Yamaha XT660Z Tenere Workshop Repair manual

SERVICE MANUAL 2008 11D-F8197-E0 XT660Z

XT660Z (2008) SERVICE MANUAL © 2008 by Yamaha Motor Italia S.p.A. First edition, May 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Italia S.p.A. is expressly prohibited. Printed in Italy

EAS00020 NOTICE This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual.Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Italia S.p.A. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. EAS00040 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE- TY IS INVOLVED! Failure to follow WARNING instructions could result in se v ere injur y or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION:

EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic.Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1” is shown at the top of each page. • Sub-section titles “2” appear in smaller print than the section title. • To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each removal and disassembly section. • Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step. • Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. • A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. • Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.

EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum disulfide oil 12. Wheel bearing grease 13. Lithium-soap-based grease 14. Molybdenum disulfide grease 15. Apply locking agent (LOCTITE ® ) 16. Replace the part with a new one. New 1 2 3 4 5 7 8 6 9 11 10 12 14 13 15 16

GENERAL INFORMATION TABLE OF CONTENTS 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL INJECTION SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9

GENERAL INFORMATION IDENTIFICATION............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER..................................................... 1-1 MODEL LABEL ......................................................................................... 1-1 FEATURES ..................................................................................................... 1-2 OUTLINE OF THE FI SYSTEM ................................................................ 1-2 FI SYSTEM ............................................................................................... 1-3 INSTRUMENT FUNCTIONS .................................................................... 1-4 IMPORTANT INFORMATION ........................................................................ 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY ........................... 1-7 REPLACEMENT PARTS .......................................................................... 1-7 GASKETS, OIL SEALS AND O-RINGS ................................................... 1-7 LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-7 BEARINGS AND OIL SEALS ................................................................... 1-8 CIRCLIPS ................................................................................................. 1-8 CHECKING THE CONNECTIONS ................................................................ 1-9 SPECIAL TOOLS ...........................................................................................1-10 1

1-1 IDENTIFICATION 1  IDENTIFICATION EAS00170 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS00180 MODEL LABEL The model label “1” is affixed to the frame under the seat. This information will be needed to order spare parts.

1-2 FEATURES EAS00019 FEATURES EAS00896 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxil- iary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for engines to deliver more perform- ance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner.To accommodate this need, this model has adopted an electroni- cally controlled fuel injection (FI) system in place of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to re- alize cleaner exhaust gases. 1. Fuel tank 2. Engine trouble warning light 3. Ignition coil 4. Spark plug 5. Fuel pump 6. Idling adjustment screw 7. Throttle position sensor 8. Intake air pressure sensor 9. Air filter case 10. ECU 11. Lean angle cut-off switch 12. Catalytic converter 13. Fuel injection system relay 14. Battery 15. Intake air temperature sensor 16. Coolant temperature sensor 17. Fuel injector 18. Crankshaft position sensor 19. O 2 sensor 20. Air induction system solenoid 21. Air cut-off valve

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2008 Yamaha XT660Z Tenere Workshop Repair manual

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