Yamaha SZR660 Service Repair Workshop Manual 1995-1998

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Typ: Motorcycle

Anbieter:

Art.-Nr: 123503

Stichworte: 1995 1996 1997 1998 Misc Motorcycle Motorcycles SZR660 Yamaha

Produktvarianten

Beschreibung

This manual pertains to the SZR660, specifically covering models produced between 1995 and 1998. The SZR660, often recognized within the Ténéré family, is a capable middleweight adventure touring motorcycle engineered for versatility, suitable for both long-distance travel and diverse terrain. Its design emphasizes renowned reliability and performance, offering a robust platform for riders seeking adventure. The 660cc parallel-twin engine, coupled with a 5-speed transmission and durable chassis, provides a balanced riding experience. This comprehensive Service Repair Workshop Manual is your definitive guide to understanding, maintaining, and repairing your SZR660. It provides in-depth coverage of all major systems, including the engine, transmission, fuel, ignition, cooling, electrical, frame, suspension, brakes, wheels, tires, and bodywork. Detailed procedures for routine maintenance, troubleshooting, disassembly, assembly, and adjustments are clearly outlined. Technical specifications, torque values, and wiring diagrams are included to ensure accurate diagnostics and repairs, empowering owners and technicians to keep this vehicle in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SZR660

Model Variant:

Super Tenere

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

Yamaha SZR660 owners, independent motorcycle repair shops, and DIY enthusiasts.

Value Proposition:

Provides dealership-level repair information for DIY and professional mechanics, enabling cost-effective maintenance and repairs.

Competitive Analysis

Competitor Manuals:

This manual is designed to be as comprehensive as the original Yamaha factory service manual, offering superior detail compared to generic repair guides.

Key Features

Authenticity:

Vehicle-specific information, not generic, mirroring the content used by authorized technicians.

Completeness:

A-Z coverage for all models and repairs within the specified production years.

Accessibility:

Instant download for immediate access to critical repair data.

📋 Manual Details

Coverage Areas

Years Covered:

1995, 1996, 1997, 1998

Model Variants Covered:

All models and configurations within the specified year range

Page Count

Estimated Page Count:

Approximately 300-400 pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, diagnostics, tuning, and specifications.

Transmission:

Gearbox, clutch, shifting mechanisms, lubrication, and troubleshooting.

Fuel System:

Carburetor(s) (likely Mikuni), fuel pump, fuel lines, filters, and tuning.

Ignition System:

CDI, ignition timing, spark plugs, coils, and wiring diagrams.

Cooling System:

Radiator, fan, hoses, coolant specifications, and thermostat.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation, and wiring diagrams.

Frame And Suspension:

Frame inspection, fork overhaul, rear shock absorber service, linkages, and adjustments.

Brakes:

Hydraulic brake system, caliper service, master cylinder, brake fluid specifications, bleeding procedures, and disc/pad replacement.

Wheels And Tires:

Tire pressure, wheel bearing service, spoke tensioning, and recommended tire sizes.

Exhaust System:

Muffler and pipe inspection, gasket replacement, and tightening procedures.

Bodywork And Fairings:

Fairing removal and installation, seat service, and minor body repairs.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication points, and general inspection.

Troubleshooting Guides:

Systematic diagnosis of common problems with step-by-step solutions.

Disassembly And Assembly:

Detailed instructions for taking apart and reassembling major components.

Rebuild Procedures:

Complete rebuild guides for engine, carburetor, and suspension components.

Adjustments:

Carburetor synchronization, valve clearance, chain tension, and brake lever adjustments.

Wiring Diagrams:

Comprehensive electrical schematics for accurate troubleshooting and repair.

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic user maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic procedures and fault code interpretation (if applicable to the era's technology).

Component Specifications:

Detailed torque values, clearances, tolerances, and material specifications.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text for quick information retrieval.

Print Quality

Print Quality:

High-resolution scans suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 5-valve, Parallel-twin

Engine Displacement:

660 cc

Bore X Stroke:

71.0 mm x 82.0 mm (typical for this engine family)

Compression Ratio:

9.0:1 (typical)

Performance

Horsepower:

Approximately 46-50 HP @ 6000 RPM (estimated, varies by market and tuning)

Torque:

Approximately 5.6 kg-m (55 Nm) @ 4500 RPM (estimated)

Fuel System

Carburetor Type:

Twin Mikuni CV (Constant Velocity) carburetors (e.g., Mikuni BSR34 or similar)

Fuel Capacity:

Approximately 15 Liters (3.9 US gallons)

Lubrication System

Oil Capacity With Filter:

Approximately 2.3 Liters (2.4 US quarts)

Recommended Oil Grade:

Yamalube 10W-40 or equivalent API SG/SH/SJ or JASO MA.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Final Drive:

O-ring sealed chain drive

Gear Ratios:

Detailed ratios provided within the manual (e.g., 1st: 2.846, 2nd: 1.875, 3rd: 1.333, 4th: 1.083, 5th: 0.917)

📐 Dimensions

Exterior

Length:

Approximately 2255 mm (88.8 inches)

Width:

Approximately 870 mm (34.3 inches)

Height:

Approximately 1320 mm (52.0 inches)

Weights

Dry Weight:

Approximately 192 kg (423 lbs)

Wet Weight:

Approximately 212 kg (467 lbs) (estimated with fluids)

Wheels And Tires

Front Tire Size:

90/90-21M/C 54S

Rear Tire Size:

130/80-17M/C 65S

Front Wheel Type:

Spoked, 21-inch

Rear Wheel Type:

Spoked, 17-inch

🛡️ Safety Features

Ratings

Safety Features:

While specific crash ratings are not typical for motorcycles of this era, the manual covers safety-critical systems like brakes and lighting.

Active Features

Braking System:

Dual disc front brakes, single disc rear brake for robust stopping power.

Passive Features

Lighting System:

Halogen headlamp, taillight, brake lights, and turn signals for visibility.

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, speedometer, odometer, trip meter, and indicator lights. Basic but functional for the era.

Driver Assistance

Not typically equipped on this model.

Connectivity

Charging Port:

No factory USB or 12V accessory port; aftermarket installation may be covered in the manual.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 6,000 km (3,700 miles), clean and re-oil if necessary.

Spark Plug Replacement:

Every 12,000 km (7,500 miles) or as needed based on inspection.

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain.

Fluid Specifications

Brake Fluid:

DOT 4.

Coolant:

Yamaha Coolant or a 50/50 mix of ethylene glycol and distilled water.

Known Issues

Common Wear Items:

Cam chain tensioner (can become noisy), regulator/rectifier (prone to failure in some Yamaha models of this era), carburetor jetting sensitivity to altitude and modifications.

Preventative Maintenance:

Regular cleaning of the air filter and correct chain adjustment are crucial for engine longevity.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha has a long-standing reputation for producing reliable, performance-oriented motorcycles across various categories, including adventure touring and dual-sport.

Model Evolution

Szr660 Development:

The SZR660 (often referred to as the XTZ660 Ténéré or similar variants) was developed as a capable middleweight adventure touring motorcycle, built to handle diverse terrain and long-distance travel.

Production

Production Period:

The XTZ660 platform spanned several years, with this manual specifically covering the 1995-1998 model years.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The Yamaha Ténéré line is widely respected in the adventure touring community for its durability and off-road capability. Specific awards for the SZR660 model are less common but it's recognized as a solid performer in its class.