Yamaha SZR660 1995 Factory Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 146120

Stichworte: 1995 Marine Motorcycle Sterndrive SZR660 Yamaha

Produktvarianten

Beschreibung

The 1995 Yamaha SZR660 is a distinctive sportbike motorcycle that masterfully blends agile handling with the robust torque of a large-displacement single-cylinder engine. Engineered for riders who appreciate a unique riding experience, it offers a compelling combination of performance and character, suitable for both daily commuting and spirited excursions. Its design philosophy prioritizes a lightweight, nimble platform, making it a standout choice in its class, known for its engaging ride and hallmark reliability. This comprehensive Factory Service Repair Manual provides detailed guidance for the maintenance and repair of your 1995 Yamaha SZR660. Covering all essential systems, including the engine, fuel system, transmission, brakes, and electrical components, this manual offers step-by-step procedures for routine maintenance, diagnostics, and complete overhauls. With clear explanations and technical specifications, it is an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SZR660

Year:

Vehicle Type:

Sportbike Motorcycle

Codes

Vin Prefix:

👋 Introduction

Market Position

Category:

Lightweight Supermoto / Performance Sportbike

Competitive Analysis

Competitors:

Ducati Monster 600, Honda XR650L, Suzuki DR650SE (in spirit, though SZR660 was more road-focused).

Key Features

Design Philosophy:

Designed to blend sportbike handling with the torquey power of a larger single-cylinder engine, offering a unique riding experience.

Target Audience:

Riders seeking an agile, characterful motorcycle with accessible performance for both commuting and spirited riding.

📋 Manual Details

Coverage Areas

Primary Coverage:

1995 Yamaha SZR660

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, diagnosis, and repair of the 660cc single-cylinder engine.

Fuel System:

Carburetor (Mikuni BSR36) tuning, cleaning, rebuilding, and fuel pump operation.

Ignition System:

CDI ignition system, spark plug specifications, timing checks, and troubleshooting.

Cooling System:

Liquid cooling system, radiator, fan operation, coolant specifications, and bleeding procedures.

Transmission:

Five-speed gearbox, clutch operation, adjustment, replacement, and gear oil specifications.

Drivetrain:

Chain drive system, sprocket inspection, adjustment, and lubrication recommendations.

Suspension:

Front telescopic forks (inverted), rear monoshock, adjustment procedures, oil types, and seals.

Brakes:

Front and rear disc brake systems, caliper service, hydraulic fluid specifications, bleeding, and pad replacement.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, charging system (stator/rectifier), fuses, and relays.

Chassis And Frame:

Frame inspection, steering head bearing service, and general chassis component checks.

Bodywork:

Fairing removal and installation, seat, fuel tank, and other body panel service.

Procedures Included

Maintenance:

Routine inspections, lubrication, filter changes, fluid checks and changes, chain adjustment, brake checks.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues with symptom-based guides.

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.

Overhaul:

Complete engine rebuild procedures, including piston, ring, valve, and crankshaft service.

Adjustment:

Carburetor synchronization, throttle cable, clutch cable, and suspension adjustments.

Technical Depth

Depth:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Readability:

High-resolution scans, clear text and diagrams.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, liquid-cooled, single-cylinder

Displacement:

659 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

9.5:1

Performance

Horsepower Est:

48-50 HP @ 6500 RPM (approximate, depending on market regulations)

Torque Est:

58 Nm (43 lb-ft) @ 5000 RPM (approximate)

Fuel System

Carburetor:

Mikuni BSR36 (single)

Fuel Capacity:

16 Liters (4.2 US gal)

Lubrication System

Oil Type:

Yamalube 4 (or equivalent API SG or higher, SAE 10W-40, 20W-40, or 20W-50)

Oil Capacity:

2.6 Liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

2135 mm (84.1 in)

Width:

750 mm (29.5 in)

Height:

1160 mm (45.7 in)

Wheelbase:

1460 mm (57.5 in)

Ground Clearance:

145 mm (5.7 in)

Weights

Dry Weight:

178 kg (392.4 lbs)

Wet Weight Est:

195 kg (430 lbs)

🛡️ Safety Features

Ratings

Safety Focus:

Standard motorcycle safety features for its era.

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Passive Features

Frame Construction:

Steel frame providing structural integrity.

Lighting:

Full headlight, taillight, and turn signal system for visibility.

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, speedometer, odometer, trip meter, and indicator lights.

Driver Assistance

Not equipped.

Connectivity

Not equipped (carbureted).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 4,000 km (2,500 miles) or 6 months.

Air Filter Inspection:

Every 4,000 km (2,500 miles).

Spark Plug Replacement:

Every 10,000 km (6,000 miles).

Chain Adjustment:

Every 2,000 km (1,200 miles) or as needed.

Valve Clearance Check:

Every 20,000 km (12,000 miles).

Fluid Specifications

Coolant Type:

High-quality ethylene glycol-based antifreeze coolant (50% solution with distilled water).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid.

Fork Oil Type:

Yamaha Fork Oil 10W or equivalent.

Known Issues

Potential Wear Items:

Cam chain wear, carburetor jetting sensitivity, fork seal leaks, clutch wear are common for this age and type of bike.

Electrical Gremlins:

Age-related electrical connector corrosion or loosening can cause intermittent issues.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha Motor Company is a globally recognized manufacturer of motorcycles, marine products, and other motorized equipment, known for innovation and performance.

Model Evolution

Szr Lineage:

The SZR series, particularly the SZR660, was a niche offering from Yamaha, combining elements of sportbikes and supermotos, leveraging their established single-cylinder engine technology.

Production

Production Period:

Mid-1990s (primarily 1992-1996 for the SZR660).

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Market Reception:

Praised for its unique blend of performance and handling in its segment, though not a mass-market seller.