Installation Instructions for Engine Gasket Set Compatible with XT660Z XTZ660 Tenere 660 (2008-2015)

Tools Required:

1. Socket Set - For removing and installing bolts and nuts
2. Torque Wrench - To ensure proper tightness according to specifications
3. Screwdriver Set - For various screws; both flathead and Phillips
4. Pry Bar - To assist in removing old gaskets if needed
5. Gasket Scraper - To clean old gasket material off surfaces
6. Rags or Clean Cloths - For cleaning engine surfaces before installation
7. Engine Oil or Gasket Sealant (optional) - For lubrication or additional sealing if required
8. Gloves - To keep your hands clean and protect them during installation
9. Safety Glasses - To protect your eyes while working

Installation Steps:

1. Preparation:

   • Ensure the engine is cool and the motorcycle is on a stable surface.
   • Disconnect the battery to prevent any electrical issues.

2. Remove Old Gaskets:

   • Use a gasket scraper to carefully remove old gaskets from the crankcase, clutch cover, and cylinder surfaces.
   • Clean all surfaces thoroughly with rags.

3. Install New Gaskets:
   -Align the new gaskets from the Engine Gasket Set with the corresponding surfaces.

   • Ensure that all holes and passages are properly aligned.

4. Reassemble Components:

   • Reattach the crankcase, clutch cover, and cylinder as per the manufacturer's specifications.
   • Hand-tighten the bolts/nuts initially to hold the components in place.

5. Torque Bolts:

   • Using a torque wrench, tighten the bolts/nuts to the specified torque values ​​as per the service manual. Follow proper tightening sequences if specified.

6. Final Checks:

   • Inspect the installation to ensure all gaskets are seated properly and everything is connected securely.
   • Reconnect the battery.

7. Start Engine:

   • Start the engine and let it run for a few minutes. Check for any leaks around the newly installed gaskets.

8. Routine Maintenance:

   • Keep an eye on gasket performance and replace them as needed to avoid leaks and maintain optimal engine performance.

Note: Always refer to your service manual for specific instructions and torque specifications tailored to your motorcycle model.

Please make sure to work safely and at your own pace. Happy riding!