Category:
Lightweight Supermotard / Sportsbike
Target Audience:
Enthusiasts and owners seeking to perform maintenance, repairs, and modifications on their Yamaha SZR660.
Competitors:
Likely competed with other similarly sized single-cylinder sportbikes or supermotos from brands like Honda (e.g., XR series), Suzuki (e.g., DR-Z series), and Kawasaki (e.g., KLX series) during its production era, offering a more road-biased Supermotard experience.
Vehicle Focus:
Agile handling, torquey single-cylinder engine, sporty design.
Manual Utility:
Empowers owners to maintain and repair their motorcycle, saving on dealership costs and fostering a deeper understanding of the machine.
Engine:
Complete engine disassembly, assembly, tuning, internal components, cooling system, lubrication system, fuel system (carburetion/injection depending on specific market variant), exhaust system.
Transmission:
Clutch, gearbox (transmission internals), shift mechanism, lubrication.
Chassis And Suspension:
Frame, front forks (suspension), rear shock absorber, swingarm, bearings, linkages.
Brakes:
Front and rear brake systems (hydraulic/mechanical), calipers, master cylinders, brake lines, discs, pads, bleeding procedures.
Electrical System:
Ignition system, starting system, charging system (alternator, stator, regulator/rectifier), lighting, instrumentation, wiring diagrams, battery service.
Fuel System:
Fuel tank, fuel lines, fuel pump (if applicable), carburetor(s) or fuel injection system (depending on market variant), fuel filter.
Bodywork And Fittings:
Fairings, seat, body panels, fenders, levers, controls, mirrors, headlights, taillights.
Wheels And Tires:
Wheel removal/installation, spoke tensioning (if applicable), tire changing, tire pressure specifications.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid changes, coolant checks, spark plug replacement, air filter cleaning/replacement.
Repair:
Detailed step-by-step repair instructions for all major and minor components. Includes engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical fault finding.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, identifying root causes of performance issues, electrical problems, and mechanical failures.
Adjustments:
Carburetor synchronization and adjustment, idle speed settings, throttle cable adjustment, clutch cable adjustment, valve clearance adjustments.
Specifications And Data:
Torque specifications, clearances, fluid capacities, electrical specifications, engine timing.
Depth:
Comprehensive, from basic owner maintenance to complete workshop-level overhauls and diagnostics. Suitable for both amateur mechanics and professional technicians.
Diagrams And Illustrations:
Detailed exploded views, assembly diagrams, wiring schematics, and repair illustrations to guide disassembly, re-assembly, and component identification.
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, Windows 7, 8, and newer operating systems).
Quality:
High-quality digital reproduction of original workshop manual content, ensuring clarity of text and diagrams.
Type:
Digital Download (not a physical binding).
Type:
N/A (Digital Format)
Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder.
Displacement:
660cc (approximate, common for this engine family used in various Yamaha models).
Bore X Stroke:
Specifics not provided but typically around 100mm x 84mm for this engine class.
Compression Ratio:
Likely in the range of 9.5:1 to 10.5:1.
Horsepower:
Estimated 40-50 HP (actual figures vary by market and specific tune).
Torque:
Strong low-to-mid range torque characteristic of a 660cc single.
Induction:
Carburetor(s) (e.g., Mikuni CV or Flatslide) or potentially early fuel injection depending on the specific model year and market. Manual will detail the specific system.
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended.
System:
Wet sump or Dry sump (depending on exact variant, likely wet sump for this application). Manual specifies oil type and capacity.
Coolant Type:
Yamaha Performance Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Manual will specify exact type and mix ratio.
Type:
Constant mesh, 5-speed or 6-speed sequential gearbox.
Type:
N/A (typically no optional transmissions for this model).
Clutch:
Wet, multi-plate clutch, cable operated. Manual covers clutch plate replacement, adjustment, and mechanism.
Final Drive:
Chain drive. Manual includes chain lubrication, adjustment, and sprocket replacement procedures.
Transmission Oil Type:
Yamalube SAE 10W-40 or SAE 20W-40 API SG or higher motorcycle oil. Manual will specify precise viscosity and API rating requirements.
Length:
Specific dimensions not provided, but typical for a naked sportbike/supermoto.
Width:
Specific dimensions not provided.
Height:
Specific dimensions not provided.
Dry Weight:
Likely in the range of 140-155 kg (dry).
Wet Weight:
Wet weight not specified but will be higher than dry weight due to fluids.
Front Tire Size:
Typically 110/70-17 or similar.
Rear Tire Size:
Typically 140/70-17 or 150/60-17 or similar.
Front Wheel Size:
17-inch.
Rear Wheel Size:
17-inch.
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months, whichever comes first. Manual will provide exact interval and oil capacity.
Spark Plug Replacement:
Approximately every 10,000-15,000 km, depending on plug type. Manual will specify correct plug type and gap.
Valve Clearance Check:
Typically around 10,000-20,000 km. Critical for engine performance and longevity. Manual details the procedure and specifications.
Engine Oil Type:
Yamalube 4-stroke motorcycle oil (e.g., SAE 10W-40 or 20W-40, API SG or higher). Manual will provide exact specifications.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies the exact type required for both front and rear systems.
Coolant Type:
Pre-mixed or concentrated ethylene glycol-based coolant with corrosion inhibitors. Manual specifies exact type and mixture ratio (typically 50/50 with distilled water).
Common Wear Items:
Clutch wear, chain and sprockets, brake pads, fork seals, exhaust baffle deterioration. Manual provides guidance on inspection and replacement.
Engine Specific Considerations:
While generally robust, potential issues with cam chain tensioners or stator reliability can occur with age. The manual provides diagnostic steps for these. Overheating can occur if cooling system is neglected.
Legacy:
Yamaha is renowned for its high-performance motorcycles, innovation, and racing heritage across various disciplines, including road racing, dirt biking, and motorsport.
Lineage:
The SZR660 leveraged Yamaha's experience with single-cylinder engines, often drawing from the XT660 engine platform used in various dual-sport and adventure models, adapted for a sportier, Supermotard application.
Manufacturing Location:
Likely manufactured in Japan or other Yamaha global production facilities.
Market Segment:
Targeted riders looking for a nimble, fun, and capable motorcycle for urban riding, commuting, and spirited weekend jaunts. Positioned as a more affordable alternative to larger sportbikes.
