Yamaha SZR660 Service Repair Manual 95-98

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Typ: Motorcycle

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Art.-Nr: 122416

Stichworte: 1995 1996 1997 1998 Misc Motorcycle Motorcycles SZR660 Yamaha

Produktvarianten

Beschreibung

The Yamaha SZR660, produced from 1995 to 1998, is a lightweight sportbike characterized by its single-cylinder, 4-stroke, 660cc engine derived from Yamaha's XT660 platform. This model offered a distinct riding experience with its torquey power delivery and agile handling, positioning it within the lightweight sportbike and supermoto segments. Notable for its sporty chassis and focus on mechanical engagement, the SZR660 was engineered for riders seeking a more focused and engaging machine, distinguishing itself from multi-cylinder competitors of its era. This comprehensive service repair workshop manual provides all-encompassing coverage for Yamaha SZR660 models manufactured between 1995 and 1998. It details a wide array of maintenance and repair procedures, including engine disassembly, assembly, tuning, lubrication, cooling, fuel, ignition, and exhaust systems. The manual also covers drivetrain, chassis, electrical systems, and bodywork, along with routine maintenance, troubleshooting guides, and specific repair instructions. Essential for owners and technicians, this manual offers in-depth technical specifications and guidance to ensure the proper upkeep and repair of the vehicle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SZR660

Engine Type:

Single-cylinder, 4-stroke

Engine Code:

Likely 4BP or similar for this generation

Generation

Model Generation:

First Generation

Codes

Chassis Codes:

Likely 4GY for early models, potential variations exist

👋 Introduction

Market Position

Market Segment:

Lightweight sportbike/supermoto segment, often popular for its agility and unique styling.

Competitive Analysis

Key Competitors:

Competed against other single-cylinder 600-660cc class bikes from manufacturers like Suzuki (e.g., early SV650 variants), Aprilia, and some Italian brands, as well as some performance-oriented dual-sport or supermoto conversions.

Key Features

Distinctive Attributes:

The SZR660 was notable for its single-cylinder engine derived from Yamaha's XT660 platform, often housed in a sporty chassis. It offered a torquey power delivery and a focused riding experience, distinguishing it from multi-cylinder sportbikes of the era.

📋 Manual Details

Coverage Areas

Coverage Scope:

All repairs covered A-Z, all models 1995-1998

Page Count

Page Count:

Not explicitly stated, but implied to be comprehensive

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English (implied by product description)

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor specifics, fuel pump), ignition system, exhaust system.

Drivetrain Systems:

Transmission (gearbox internals, clutch operation, lubrication), final drive (chain and sprocket maintenance).

Chassis Systems:

Frame inspection and repair, suspension (front fork service, rear shock absorber), steering system (handlebar, triple clamps), braking system (hydraulic circuits, caliper overhaul, pad replacement, disc maintenance), wheel and tire service.

Electrical Systems:

Wiring diagrams, lighting system (headlight, taillight, indicators), charging system (stator, rectifier/regulator, battery), starting system (starter motor, solenoid), ignition control unit (CDI).

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank mounting, fender service.

Procedures Included

Maintenance Procedures:

Routine checks (oil level, coolant, tire pressure), lubrication points, chain adjustment, filter replacements, spark plug service, valve clearance adjustment.

Troubleshooting Guides:

Diagnostic charts for common starting, running, and electrical issues.

Repair And Rebuild Procedures:

Detailed step-by-step instructions for engine rebuilds, carburetor overhaul, brake system bleeding, fork seal replacement, and more.

Special Tool Requirements:

Identification of specific tools needed for certain procedures (e.g., torque wrenches, specialized engine tools).

Technical Depth

Depth Of Information:

Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed specifications, tolerances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High resolution, suitable for on-screen viewing and printing.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

660cc

Engine Configuration:

Single-cylinder, 4-stroke, SOHC, 4 valves per cylinder

Bore X Stroke:

Approximately 100 mm x 84 mm (based on XT660 engine family)

Compression Ratio:

Likely around 9.2:1 to 9.7:1 (depending on specific market tune)

Cooling System:

Liquid-cooled

Performance

Horsepower Output:

Approximately 45-50 HP (Varies by market and tuning)

Torque Output:

Approximately 5.5-6.0 kgf-m or 40-43 lb-ft (Varies by market)

Fuel System

Carburetor Type:

Likely a Mikuni BST34 or similar downdraft carburetor

Fuel Tank Capacity:

Around 15-16 Liters

Lubrication

Oil Type Specification:

Yamaha recommends Yamalube 4 (or equivalent API SG, SAE 20W-40 or 10W-30)

Oil Capacity With Filter:

Approximately 2.0 - 2.2 Liters

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2090 mm

Width:

Approx. 780 mm

Height:

Approx. 1115 mm

Wheelbase:

Approx. 1405 mm

Weights

Dry Weight:

Approx. 160 kg

Wet Weight:

Approx. 175 kg (with fluids)

🛡️ Safety Features

Ratings

Safety Certifications:

Meets relevant national and international road safety standards for motorcycles of its class.

Active Features

Braking System:

Hydraulic front disc brake (likely 2-piston caliper), Hydraulic rear disc brake (likely single-piston caliper).

Suspension Geometry:

Designed for agility and stability, contributing to safe handling characteristics.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable; this is a performance motorcycle from the mid-90s focusing on mechanicals rather than digital features.

Driver Assistance

Rider Aids:

No electronic rider aids such as ABS or traction control. Focus is on rider skill and machine feedback.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km or 6 months, whichever comes first (refer to manual for exact specifications).

Air Filter Service:

Inspect every 5,000 km, clean or replace as needed.

Spark Plug Replacement:

Recommended every 10,000-15,000 km (specific plug type and gap critical).

Valve Clearance Adjustment:

Typically every 10,000-20,000 km, or as indicated by engine noise (critical for performance and longevity).

Fluid Specifications

Brake Fluid Type:

DOT 4 or DOT 5.1 (refer to manual for specific recommendation, always use fresh fluid).

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.

Known Issues

Common Wear Items:

Clutch wear, carburetor jetting/cleaning requirements due to fuel quality variations, front fork seal leaks, potential voltage regulator issues common on older Yamahas.

Carburetor Idiosyncrasies:

Sensitivity to atmospheric conditions and fuel quality; requires periodic cleaning and precise adjustment for optimal performance.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, known for innovation and performance across various segments, from sportbikes to off-road and cruisers.

Model Evolution

Szr Development:

The SZR660 was part of Yamaha's strategy to offer unique, lighter-weight, single-cylinder performance bikes that appealed to riders seeking maneuverability and character. It leveraged proven engine technology from their dual-sport line.

Production

Production Years:

1995-1998 (as per manual coverage)

Manufacturing Location:

Primarily Japan, with potential assembly in other regions.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

Specific awards for the SZR660 are not widely documented, but it was recognized within its niche for its unique character and agile handling.

Ratings

Performance Reviews:

Contemporary reviews highlighted its lively engine, capable chassis, and fun factor, especially in urban or twisty road environments.