Yamaha XT660Z (2009-2015) Ténéré Maintenance Schedule
The Yamaha XT660Z Ténéré (a.k.a. the XTZ660) is a big-bore adventure bike/dual sport with a modern fuel-injected “thumper” engine.
The XT660Z Ténéré is part of the XT660 range of motorcycles that all share the same underlying platform, a four-stroke four-valve single-cylinder 659cc water-cooled fuel-injected engine. It is reliable, torquey, and very practical for short or long-haul riding.
The three variants in the XT660 range are:
- XT660R: The base model dual-sport. 21/17 inch tyres front and back, with a single 298mm front brake disc.
- XT660X: The street-oriented supermoto. Bigger (still single) front disc (320mm), and 17-inch tyres front and back.
- XT660Z Ténéré: 21/17 tyres (as with the base model), dual 298mm discs, long-range fuel tank (22L vs 15L in the other models), taller cowl, hand guards, engine guards, skid plate, vertically stacked bulbs.
So the XT660Z is the highest spec of all of them, but maintenance for all of them (other than brakes and tyres) is the same.
In 2018, the Yamaha XT660Z Ténéré was replaced with the Yamaha XTZ690 Ténéré 700, based on the CP2 engine from the MT-07.
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What you need to service your Yamaha XT660Z Ténéré
Servicing a fuel injected thumper is as easy as it gets. You just have one cylinder, and no carbs! You need some basic maintenance tools (you won’t need a rear stand if you already have a centre stand) and away you go.
Some parts are common to all XT660 motorcycles, but the brakes and tyres are different.
| Part | Yamaha XT660Z spec |
|---|---|
| Engine oil | The manual recommends SAE 10W30, 10W40, 15W40, 20W40, or 20W50 engine oil meeting API service SE, SF, SG or higher. This means a lot of motorcycle oils fit the mark. Yamalube 10W40 is an excellent choice — on brand, and cheap. |
| Oil filter | Standard part number is 4X7134409000. Use a Hiflofiltro HF145, which fits many models. |
| Spark plug | Manual calls for NGK CR7E. |
| Air filter | Use a K&N air filter YA-6608 which is more available and very high quality. |
| Brakes | The XT660Z has twin discs up front and one disc in the rear. EBC’s R brake pads provide good performance for this bike. Use 2 x FA172R up front, and 2 x FA101R in the rear. |
| Grease | Grease external pivot points (e.g. the swingarm shaft) with lithium soap-based grease. |
| Chain | Maintain your chain — Motul chain paste is a low-cost and mess-free way of doing it |
| Coolant | The manual doesn’t specify, but normally Japanese motorcycles use ethylene glycol-based coolant that’s silicate and borate-free to preserve the life of aluminium components. I like Honda Coolant as an effective long-life coolant. |
| ‘000 km | 1 | 10 | 20 | 30 | 40 | ||
|---|---|---|---|---|---|---|---|
| Part | ‘000 mi | 0.6 | 6 | 12 | 18 | 24 | Other interval |
| Fuel line | * Check fuel hoses for cracks or damage | ✓ | ✓ | ✓ | ✓ | Annual | |
| Spark plug | * Check condition * Clean and regap (Spark plug gapping tool) | ✓ | ✓ | ||||
| * Replace (CR7E) | ✓ | ✓ | |||||
| Valves | * Check valve clearance * Adjust | ✓ | ✓ | ||||
| Fuel injection | * Adjust engine idling speed | ✓ | ✓ | ✓ | ✓ | ✓ | Annual |
| Mufflers and exhaust pipes | * Check the screw clamps for looseness | ✓ | ✓ | ✓ | ✓ | ✓ | |
| Air induction system | * Check the air cut-off valve, reed valve, and hose for damage * Replace any damaged parts if necessary | ✓ | ✓ | ✓ | ✓ | Annual | |
| Air filter | * Replace (YA-6608) | ✓ | ✓ | ||||
| Clutch | * Check operation * Adjust | ✓ | ✓ | ✓ | ✓ | ✓ | |
| Front brake | * Check operation, fluid level, and vehicle for fluid leakage | ✓ | ✓ | ✓ | ✓ | ✓ | Annual |
| * Replace brake pads | Whenever worn to the limit | ||||||
| Rear brake | * Check operation, fluid level, and vehicle for fluid leakage | ✓ | ✓ | ✓ | ✓ | ✓ | Annual |
| * Replace brake pads | Whenever worn to the limit | ||||||
| Brake hoses | * Check for cracks or damage * Check for correct routing and clamping | ✓ | ✓ | ✓ | ✓ | Annual | |
| * Replace | Every 4 years | ||||||
| Wheels | * Check runout, spoke tightness, and for damage * Tighten spokes if necessary | ✓ | ✓ | ✓ | ✓ | ✓ | |
| Tyres | * Check tread depth and for damage * Replace if necessary * Check air pressure * Correct if necessary | ✓ | ✓ | ✓ | ✓ | Annual | |
| Wheel bearings | * Check bearings for looseness or damage | ✓ | ✓ | ✓ | ✓ | ||
| * Swingarm | * Check operation and for excessive play | ✓ | ✓ | ✓ | ✓ | ||
| * Lubricate with lithium soap-based grease | Every 50K km (30K mi) | ||||||
| Chain | * Check chain slack, alignment, and condition * Adjust and lubricate (Motul chain paste) | Every 500 km (300 mi) or when it gets wet | |||||
| Steering bearings | * Check bearing play and steering for roughness | ✓ | ✓ | ✓ | ✓ | ✓ | |
| * Lubricate with lithium soap-based grease | Every 20K km (12K mi) | ||||||
| Chassis fasteners | * Make sure that all nuts, bolts, and screws are properly tightened. | ✓ | ✓ | ✓ | ✓ | Annual | |
| Brake lever pivot shafed | * Lubricate with silicone grease | ✓ | ✓ | ✓ | ✓ | Annual | |
| Brake pedal pivot shaft | * Lubricate with silicone grease | ✓ | ✓ | ✓ | ✓ | Annual | |
| Clutch lever pivot shaft | * Lubricate with lithium soap-based grease | ✓ | ✓ | ✓ | ✓ | Annual | |
| Sidestand | * Check condition * Lubricate with lithium soap-based grease | ✓ | ✓ | ✓ | ✓ | Annual | |
| Sidestand switch | * Check operation | ✓ | ✓ | ✓ | ✓ | ✓ | Annual |
| Front fork | * Check operation and for leakage | ✓ | ✓ | ✓ | ✓ | ||
| Shock absorber | * Check operation and for leackage | ✓ | ✓ | ✓ | ✓ | ||
| Rear suspension relay arm and connecting arm pivot points | * Check operation | ✓ | ✓ | ✓ | ✓ | ||
| * Lubricate with lithium soap-based grease | ✓ | ✓ | ✓ | ✓ | |||
| Engine oil | * Change (Yamalube 10W-40) | ✓ | ✓ | ||||
| * Check oil level and vehicle for oil leakage | ✓ | ✓ | ✓ | ✓ | ✓ | Annual | |
| Engine oil filter | * Replace (HF204RC) | ✓ | ✓ | ✓ | |||
| Cooling system | * Check coolant level and vehicle for coolant leakage | ✓ | ✓ | ✓ | ✓ | Annual | |
| * Change coolant (Honda Coolant) | Every 3 years | ||||||
| Front and rear brake switches | * Check operation | ✓ | ✓ | ✓ | ✓ | ✓ | Annual |
| Moving parts and cables | * Lubricate (Protect all cable life) | ✓ | ✓ | ✓ | ✓ | Annual | |
| Throttle grip | * Check operation * Check throttle grip free play, and adjust if necessary * Lubricate cable and grip housing (Protect all cable life) | ✓ | ✓ | ✓ | ✓ | Annual | |
| Lights, signals, and switches | * Check operation * Adjust headlight beam | ✓ | ✓ | ✓ | ✓ | ✓ | Annual |
Tyre/Wheel size for the Yamaha XT660Z Ténéré
The Ténéré has bigger tyres/wheels than the supermoto, though the same as the XT660R. Here are its tyre and wheel sizes, as well as recommended pressures. Of course, find the best pressure for you, based on your characteristics, riding style, and where you are riding. Off-road, Yamaha recommends 200 kPa (29 psi) front and rear.
| Wheel | Tyre size | Tyre pressure |
|---|---|---|
| Front | 90/90-21 M/C 54S | 30-33 psi |
| Rear | 130/80-17 M/C 65S | 33-36 psi |
Non-ABS models ship with Michelin Sirac or Metzeler Tourance tyres. The ABS model ships with Pirelli Scorpions.
About the Yamaha XT660Z Ténéré
The Yamaha XT660Z Ténéré straddles the classes of “dual sport” and “adventure tourer”. It is built around the platform of the XT660R, but has better braking and a bunch of options (like a longer-range fuel tank and better weather protection) to make it more suitable for the long road.
The XT660Z also gets a dual-bulb headlamp assembly with a vertically stacked low and high beam. It looks cool, and keeps the front narrow for better aerodynamics. There’s also an optional centre stand, very useful for long trips to oil the chain or repair a wheel.
The base engine is the same four-stroke four-valve single-cylinder 659cc water-cooled fuel-injected engine. It is reliable, torquey, very practical, and easy to maintain (just one cylinder!). Power is put to the ground via a 5-speed transmission and a chain drive — so you’ll have to clean that chain regularly if (when) you head off-road.
What makes the XT660Z Ténéré unique among Japanese thumpers is that it is a more advanced motorcycle. It’s fuel-injected and it has had ABS brakes as an option for many years — something that the Japanese thumpers never got (until the 2022 KLR650, anyway). BMW did with its F650GS though.
Aside from that, the XT660Z is a real looker. The style didn’t even change dramatically with the XTZ690 Ténéré 700.
The XT660Z has moderately long-travel suspension (210mm of travel). It’s not like a motocross bike, but it’s ample for winding, dusty roads in the middle of nowhere.
The XT660Z Ténéré could also be considered the little sibling of the much bigger and heavier XTZ1200 Super Ténéré which has a large bore parallel twin engine and a shaft drive. In fact, the Ténéré name has been with Yamaha for decades.
Manual for the Yamaha XT660Z
The above maintenance table came from the manual for the XT660Z. It’s available from some regional Yamaha websites, like the one in Europe or in Australia (click on “Owners Manuals”).
