The Yamaha Tenere 660, a legendary adventurer bike, has captured the hearts of riders seeking rugged reliability and go-anywhere capability. However, even this trusty steed isn't without its quirks. While generally robust, certain issues have been reported by owners, ranging from minor annoyances to more significant concerns. Understanding these potential problems can help you make an informed purchase, maintain your Tenere effectively, and keep it running smoothly for years to come.

So, What Are the Tenere 660's Achilles' Heels?

Let's dive into some of the most common issues experienced by Tenere 660 owners:

1. The Fuel Pump Fiasco:

This is arguably the most frequently reported problem with the Tenere 660. The fuel pump, manufactured by Mitsuba, is prone to failure, especially in hot climates or when using lower-quality fuel.

  • The Symptoms: The bike might start to stutter or hesitate, especially under load. It could also become increasingly difficult to start, eventually refusing to fire up at all. Sometimes, the pump will make a high-pitched whining noise before failing.
  • The Cause: The pump's internal components can corrode or become clogged, leading to reduced fuel flow or complete pump failure. Heat exacerbates the issue.
  • The Fix: Replacement is usually the only viable solution. Many owners opt for aftermarket fuel pumps from reputable brands like Facet or Quantum, which are generally considered more reliable than the original Mitsuba unit. Regularly using fuel additives designed to clean and protect the fuel system can also help prevent future problems. Carrying a spare fuel pump on long trips is a prudent precaution.

2. Regulator/Rectifier Woes:

Another electrical gremlin that can plague the Tenere 660 is a faulty regulator/rectifier (R/R). This component is responsible for regulating the voltage from the alternator and charging the battery.

  • The Symptoms: A dying battery is the first sign. You might notice the bike is difficult to start, or the battery loses charge quickly. Other symptoms include dimming lights, erratic instrument panel readings, and even engine stalling. In severe cases, a faulty R/R can overcharge the battery, causing it to boil and potentially damage other electrical components.
  • The Cause: Overheating is the primary culprit. The stock R/R is often mounted in a location with poor airflow, leading to excessive heat buildup and eventual failure.
  • The Fix: Replacing the R/R is the standard solution. Many owners relocate the replacement unit to a location with better airflow, such as under the seat or near the front of the bike. Upgrading to a MOSFET-type R/R, which runs cooler and is generally more reliable, is also a popular modification.

3. The EXUP Valve Predicament:

The EXUP (Exhaust Ultimate Power Valve) is a valve located in the exhaust system that helps to optimize exhaust flow for improved performance. However, it can become seized or malfunction over time.

  • The Symptoms: A rough or uneven running engine, particularly at low RPMs. The bike might also feel sluggish or lack power in certain parts of the rev range. Sometimes, the check engine light will illuminate.
  • The Cause: Carbon buildup and corrosion can cause the EXUP valve to seize in either the open or closed position. Lack of regular maintenance also contributes to the problem.
  • The Fix: Regular cleaning and lubrication of the EXUP valve mechanism are crucial for preventing issues. Disassembling the valve and cleaning it thoroughly with a suitable solvent can often restore its functionality. In some cases, the valve might be too corroded to salvage and will need to be replaced. Some owners choose to remove the EXUP valve entirely and install an EXUP eliminator, which tricks the ECU into thinking the valve is still functioning correctly. This can improve performance but may also slightly increase exhaust noise.

4. Clutch Basket Chatter:

Some Tenere 660 owners have reported excessive noise coming from the clutch basket, especially when the engine is idling in neutral with the clutch engaged.

  • The Symptoms: A rattling or clattering noise emanating from the clutch area. The noise usually disappears when the clutch lever is pulled in.
  • The Cause: Wear and tear on the clutch basket components, particularly the springs and dampers, can cause excessive play and noise.
  • The Fix: Replacing the clutch basket is the most effective solution. Aftermarket clutch baskets with improved damping systems are available and can provide a quieter and smoother clutch operation. While the noise is often more of an annoyance than a functional problem, ignoring it can eventually lead to more serious clutch issues.

5. The Side Stand Switch Sensitivity:

The side stand switch is designed to prevent the bike from being ridden with the side stand down. However, it can be overly sensitive and prone to malfunction.

  • The Symptoms: The engine might cut out unexpectedly, especially when riding over bumps or rough terrain. The bike might also refuse to start if the switch is faulty.
  • The Cause: Dirt, corrosion, or physical damage can affect the switch's operation.
  • The Fix: Cleaning and lubricating the switch mechanism can sometimes resolve the issue. Adjusting the switch's position or replacing it with a new unit are other options. Some owners choose to bypass the switch entirely, but this is not recommended as it removes a safety feature.

6. Corrosion Concerns:

Like many motorcycles, the Tenere 660 is susceptible to corrosion, especially in areas exposed to moisture and road salt.

  • The Symptoms: Rust on frame components, exhaust system, and other metal parts. Corrosion on electrical connectors can lead to intermittent problems.
  • The Cause: Exposure to water, salt, and other corrosive elements. Lack of regular cleaning and maintenance.
  • The Fix: Regular cleaning and lubrication are essential for preventing corrosion. Applying protective coatings to vulnerable areas can also help. Address any existing corrosion promptly to prevent it from spreading.

7. The Soft Suspension Saga:

While the Tenere 660's suspension is adequate for general riding, it can feel soft and underdamped, especially when carrying luggage or riding off-road.

  • The Symptoms: Excessive dive under braking, wallowing in corners, and a generally unstable feeling, particularly on rough surfaces.
  • The Cause: The stock suspension components are designed for a wide range of riders and riding conditions, but they might not be ideal for heavier riders or those who frequently ride off-road.
  • The Fix: Upgrading the suspension components is a common modification. Options include replacing the fork springs and dampers with heavier-duty units, installing aftermarket shock absorbers, or even upgrading the entire fork and shock assembly.

8. Instrument Panel Fogging:

Some owners have reported fogging inside the instrument panel, particularly in humid conditions.

  • The Symptoms: Condensation or fogging inside the instrument panel, making it difficult to read the gauges.
  • The Cause: Moisture entering the instrument panel through seals or vents.
  • The Fix: Removing the instrument panel and drying it thoroughly can sometimes resolve the issue. Sealing any potential entry points with silicone sealant can help prevent future fogging.

9. The "Tick-Tick-Tick" Noise:

A ticking noise, often described as coming from the top end of the engine, is a common characteristic of the Tenere 660.

  • The Symptoms: A ticking noise that increases with engine RPM.
  • The Cause: This is often attributed to valve clearance.
  • The Fix: Checking and adjusting the valve clearances as per the service manual is crucial. This is a routine maintenance procedure that should be performed regularly. If the noise persists after adjusting the valve clearances, it could indicate other issues, such as a worn camshaft or rocker arm.

10. The Weight Factor:

Let's be honest, the Tenere 660 isn't the lightest adventure bike on the market.

  • The Symptoms: Feeling the weight, especially in challenging off-road situations or when maneuvering at low speeds.
  • The Cause: The bike's overall design and components contribute to its weight.
  • The Fix: While you can't magically make the bike lighter, you can improve its handling by upgrading the suspension, distributing weight effectively when packing luggage, and honing your riding skills.

Frequently Asked Questions (FAQs)

  • Is the Tenere 660 a reliable bike? Yes, overall, the Tenere 660 is considered a reliable motorcycle, but it has a few known issues that should be addressed. Regular maintenance is key to ensuring its longevity.
  • How often should I check the valve clearances? Yamaha recommends checking valve clearances every 20,000 km (12,000 miles). However, many owners prefer to check them more frequently, especially if they notice any unusual engine noise.
  • What fuel should I use in my Tenere 660? Yamaha recommends using premium unleaded fuel with an octane rating of 95 RON or higher. While the bike can run on lower octane fuel, it may result in reduced performance and increased fuel consumption.
  • Is the Tenere 660 good for long-distance touring? Yes, the Tenere 660 is well-suited for long-distance touring, thanks to its comfortable riding position, large fuel tank, and rugged design. Consider upgrading the seat and suspension for added comfort.
  • Where can I find parts for my Tenere 660? Parts are available from Yamaha dealers, aftermarket parts suppliers, and online retailers. Many online forums and communities dedicated to the Tenere 660 can also provide valuable information and resources.

Keeping Your Tenere 660 Running Strong

The Yamaha Tenere 660 is a fantastic adventure bike, and by being aware of these potential issues and taking proactive steps to maintain your bike, you can enjoy many years of reliable service. Regular maintenance, quality fuel, and addressing problems promptly are key to keeping your Tenere 660 running smoothly.