Vehicle Segment:
Lightweight sportbike / naked bike segment, popular for urban commuting and spirited riding.
Key Competitors 1995:
Kawasaki ER-5, Honda CB500, Suzuki GS500E, Ducati Monster (though typically higher price point).
Motorcycle Philosophy:
Focus on a balance of performance, agility, and reliability, often featuring a single-cylinder engine for torque and simplicity.
Manual Value:
Essential tool for owners and technicians to maintain, diagnose, and repair the SZR660, enabling cost savings and ensuring optimal performance.
Primary Users:
Yamaha SZR660 owners, independent motorcycle mechanics, service technicians.
Engine Systems:
Engine overhaul, cooling system, carburetor systems, lubrication, ignition, starting system, exhaust system
Chassis Systems:
Frame, suspension (front and rear), steering, braking system (front and rear), wheels and tires, final drive
Electrical Systems:
Wiring diagrams, lighting system, instrumentation, charging system (stator, regulator/rectifier), battery, ignition system components
Maintenance Procedures:
Periodic inspections, adjustments (valve clearance, chain tension, brake levers, clutch lever), lubrication points, filter replacement, spark plug maintenance
Repair Procedures:
Engine rebuild (top-end and bottom-end), carburetor cleaning and rebuilding, brake caliper overhaul, suspension fork service, electrical component testing and replacement
Troubleshooting Guidance:
Diagnostic flowcharts, symptom-based troubleshooting for engine, electrical, and chassis issues
Diagnostic Capabilities:
Detailed diagnostic procedures, including electrical testing with multimeter specifications and troubleshooting common failure points.
Rebuild Information:
Comprehensive engine teardown, overhaul, and reassembly instructions with torque specifications and critical clearance measurements.
Special Tool Requirements:
Likely specifies necessary special tools for specific procedures (e.g., flywheel puller, valve spring compressor), though not explicitly listed.
Digital Format:
PDF (Portable Document Format)
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Reader Requirement:
Requires Adobe PDF Reader (freely available).
Printability:
Designed to be printable for physical use in a workshop environment.
Digital Binding:
N/A (Digital file)
Digital Paper Simulation:
Simulates standard workshop manual paper types for clarity of diagrams and text.
Engine Type:
Four-stroke, liquid-cooled, DOHC, parallel-twin cylinder engine.
Displacement:
660cc (This is a likely designation, exact displacement for SZR660 may vary slightly based on market or specific variant, often derived from XTZ660/TDM600 platforms).
Bore X Stroke:
Specifications not provided in product description, but typical for this displacement might be around 80mm x 66mm.
Compression Ratio:
Specifications not provided in product description, but likely in the range of 9.5:1 to 10.5:1.
Horsepower Estimate:
Estimated 50-60 HP at the crank, depending on tuning and market specifications.
Torque Estimate:
Estimated 55-65 Nm at the crank, providing good low-to-mid range pull.
Fuel Delivery:
Carburetor (likely dual Mikuni VM or similar).
Carburetor Size:
Likely 34mm or 36mm dual carburetors.
Oil Capacity:
Approximately 2.5-3.0 liters with oil filter change. Specific capacity would be in the manual.
Cooling Type:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.
Transmission Type:
Constant mesh, 6-speed sequential gearbox.
Optional Transmission:
N/A (Typically no optional transmissions offered for this model).
Clutch Type:
Wet, multiple-disc clutch, cable operated.
Final Drive:
O-ring sealed chain drive.
Length Estimate:
Approximately 2050mm (80.7 inches).
Width Estimate:
Approximately 740mm (29.1 inches).
Height Estimate:
Approximately 1100mm (43.3 inches).
Dry Weight Estimate:
Around 170 kg (375 lbs).
Wet Weight Estimate:
Around 185 kg (408 lbs) with all fluids.
Fuel Tank Capacity:
Approximately 16 liters (4.2 US gallons).
Safety Certification:
Likely meets or exceeds all relevant national and international motorcycle safety standards for its era.
Braking System Front:
Dual disc brakes with dual-piston calipers.
Braking System Rear:
Single disc brake with single-piston caliper.
Suspension Front:
Telescopic, cartridge-type front forks. Likely 41mm stanchion diameter.
Suspension Rear:
Monoshock swingarm with adjustable preload.
Lighting:
Halogen headlight, LED taillight, standard turn signals.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, warning lights.
Infotainment System:
N/A (This model predates modern infotainment systems; basic analog instrumentation only).
Driver Assistance Features:
N/A (No electronic rider aids like ABS or traction control were standard or optional on this model).
Connectivity Features:
N/A (No Bluetooth, USB, or other connectivity features).
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.
Air Filter Cleaning Interval:
Every 6,000-10,000 km (3,700-6,200 miles), or more frequently in dusty conditions.
Valve Clearance Check:
Initial check at 1,000 km (600 miles), then every 10,000-15,000 km (6,200-9,300 miles).
Engine Oil Grade:
Yamalube 10W-40 or equivalent API SG, JASO MA certified motorcycle oil.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Specifications:
Yamaha Coolant (Blue) or equivalent ethylene glycol-based, long-life coolant (50/50 mix with distilled water).
Common Wear Items:
Chain and sprockets, brake pads, clutch plates, fork seals due to age and mileage.
Electrical Gremlins:
Corrosion in connectors, aging wiring harness, regulator/rectifier failure are common in bikes of this age. Carburetor gumming from fuel sitting.
Engine Longevity:
Generally robust engines, but regular maintenance is key to longevity. Overheating can cause head gasket issues.
Yamaha Heritage:
Yamaha Motor Company is a Japanese manufacturer with a long history in motorcycles, engines, and musical instruments, renowned for innovation and performance.
Szr660 Lineage:
The SZR660 was part of Yamaha's strategy to offer a lightweight, versatile sportbike, often utilizing proven engine platforms from their dual-sport or touring models (like the TDM/XTZ series).
Production Years:
1995-1997 (First Generation). Minor updates may have occurred in subsequent years, but the core platform remained consistent.
Manufacturing Location:
Likely manufactured in Japan, though specific assembly plants could vary by market.
Motorsport Heritage:
While the SZR660 itself might not have specific racing awards, Yamaha has a deep history in racing (MotoGP, WSBK) which influences their road bike development.
Consumer Reviews Era:
Generally well-regarded for its agility, smooth parallel-twin engine, and comfortable riding position for its class.
Emissions Standards:
Met prevailing emissions standards for 1995 in its target markets (e.g., Euro 1 or equivalent).
