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Yamaha SZR660 Service Repair Workshop Manual

$16.99
$16.99
The Yamaha SZR660 is a motorcycle produced from 1995 to 1998, celebrated for its powerful 660cc single-cylinder engine, agile handling, and distinctive styling. This model, often positioned within the sportbike...
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Typ: Motorcycle
Anbieter:
Yamaha
Art.-Nr: 120627
Stichworte: Misc Motorcycle Motorcycles SZR660 Yamaha
Yamaha SZR660 Service Repair Workshop Manual
The Yamaha SZR660 is a motorcycle produced from 1995 to 1998, celebrated for its powerful 660cc single-cylinder engine, agile handling, and distinctive styling. This model, often positioned within the sportbike or naked bike segment, offers a spirited riding experience characterized by its punchy power delivery. Engineered with a focus on performance and rider engagement, the SZR660 has garnered appreciation among enthusiasts for its robust mechanicals and straightforward design, making it a capable machine for both spirited riding and daily use. This comprehensive service repair workshop manual provides essential information for owners and technicians to maintain and repair the Yamaha SZR660. Covering all variants from the production years 1995-1998, the manual details procedures for engine disassembly and assembly, fuel system maintenance, ignition system diagnosis, transmission and clutch service, cooling system upkeep, and brake system overhauls. It also includes guidance on electrical systems, frame and suspension adjustments, bodywork, and routine maintenance tasks, offering in-depth knowledge for troubleshooting and ensuring the longevity of the vehicle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
SZR660
Type:
Motorcycle
Codes
Engine Code:
4BR
Chassis Code:
4BR
👋 Introduction
Market Position
Segment:
Sportbike/Naked Bike
Target Audience:
Enthusiasts and owners seeking to maintain, repair, or modify their Yamaha SZR660.
Competitive Analysis
Segment Competitors:
Honda CB500, Ducati Monster 600, Kawasaki ER-5.
Key Features
Features:
Powerful single-cylinder engine, agile handling, distinctive styling.
Manual Value:
Provides essential information for DIY maintenance, saving on labor costs and ensuring proper upkeep.
📋 Manual Details
Coverage Areas
Applicable Years:
1995, 1996, 1997, 1998
Covered Models:
All Yamaha SZR660 variants
Page Count
Estimated Pages:
400+
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Full disassembly, assembly, diagnosis, and repair of the 4-stroke, liquid-cooled, 5-valve, single-cylinder engine.
Fuel System:
Carburetor service, adjustment, cleaning, and troubleshooting (Mikuni BST34).
Ignition System:
CDI ignition system diagnosis, spark plug specifications, timing checks.
Transmission:
5-speed constant mesh gearbox, clutch operation, inspection, adjustment, and repair.
Cooling System:
Radiator, fan, hoses, thermostat, and coolant specifications and maintenance.
Frame And Suspension:
Front fork (Telescopic, cartridge type) overhaul, rear shock absorber inspection and adjustment, frame inspection.
Brakes:
Front and rear hydraulic disc brake systems, caliper service, pad replacement, bleeding procedures, master cylinder.
Electrical System:
Wiring diagrams, battery, charging system (alternator, rectifier/regulator), starter motor, lighting, indicators, switches, fuses.
Exhaust System:
Muffler and pipe inspection and replacement.
Wheels And Tires:
Wheel bearing inspection, tire pressure recommendations, wheel removal and installation.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, and other body panels.
Procedures Included
Maintenance:
Routine checks, lubrication, filter changes, spark plug replacement, chain adjustment.
Troubleshooting:
Diagnostic charts for common problems, electrical system fault finding.
Repair:
Step-by-step instructions for component disassembly, reassembly, and repair.
Adjustment:
Carburetor synchronization, clutch and brake lever free play, suspension settings.
Diagnostics:
Component testing, electrical circuit analysis.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and electrical system diagnostics.
Detail Level:
Highly detailed with clear explanations, diagrams, and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Printability:
Printable pages for on-the-go reference.
Print Quality
Quality:
High-resolution scans for clear text and sharp images/diagrams.
Binding Type
Binding:
N/A (Digital Product)
Paper Type
Paper:
N/A (Digital Product)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, 5-valve, Single Cylinder
Displacement:
660 cc
Bore X Stroke:
100.0 mm x 85.0 mm
Cooling System:
Liquid-cooled
Compression Ratio:
9.8:1
Performance
Horsepower:
Approx. 47 hp @ 6,000 rpm (Manufacturer data may vary by region)
Torque:
Approx. 60 Nm @ 4,500 rpm (Manufacturer data may vary by region)
Fuel System
Carburetor:
Mikuni BST34 (x1)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Fuel Tank Capacity:
15 Liters (approx.)
Lubrication
Oil Type:
SAE 10W-40 API SG or higher, JASO MA compliant motorcycle oil
Oil Capacity:
2.5 Liters (with filter change)
🔧 Transmission
Standard
Type:
Constant mesh, 5-speed
Gear Ratios:
Provided in manual (specific ratios for each gear).
Features
Clutch Type:
Wet, multiple-disc, cable-actuated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
2,085 mm
Width:
730 mm
Height:
1,125 mm
Wheelbase:
1,405 mm
Ground Clearance:
160 mm
Weights
Dry Weight:
165 kg
Wet Weight:
178 kg (approx., with all fluids)
Load Capacity:
Recommended rider and passenger weight limits provided in manual.
🛡️ Safety Features
Ratings
Safety Standards:
Meets relevant safety standards for motorcycles of its era.
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Suspension:
Telescopic front forks and adjustable rear monoshock contribute to stability and handling.
Passive Features
Lighting:
Headlight, taillight, brake lights, and turn signals for visibility.
Chassis Design:
Steel tube frame for structural integrity.
💡 Technology Features
Infotainment
Features:
Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, and warning lights.
Driver Assistance
Features:
None (This era of motorcycle typically did not feature electronic rider aids).
Connectivity
Features:
None
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 km or 6 months, whichever comes first.
Air Filter Cleaning:
Every 3,000 km; replacement as needed.
Spark Plug Replacement:
Every 6,000 km or as per inspection.
Valve Clearance Check:
Every 10,000 km or annually.
Fluid Specifications
Coolant Type:
Yamaha-approved ethylene glycol-based coolant (50% solution with distilled water).
Brake Fluid Type:
DOT 4
Known Issues
Carburetor Tuning:
Can be sensitive to altitude and atmospheric conditions, requiring occasional fine-tuning for optimal performance.
Oil Leaks:
Check for leaks around the oil filter and drain plug, and the output shaft seal.
Electrical Connections:
Ensure all electrical connectors are clean and secure to prevent intermittent faults.
Common Repairs
Fork Seals:
Regular inspection and replacement of fork seals as needed to prevent oil leaks.
Chain And Sprockets:
Regular maintenance and timely replacement of the drive chain and sprockets.
📚 Vehicle History
Brand Heritage
Heritage:
Yamaha Motor Corporation is renowned for its high-performance motorcycles and engineering expertise across various motorized vehicles.
Model Evolution
Predecessors:
While not a direct evolution of a single model, it shares lineage with Yamaha's successful single-cylinder performance bikes.
Key Attributes:
The SZR660 was designed as a lightweight, sporty, and user-friendly motorcycle, often appreciated for its punchy single-cylinder power delivery.
Production
Production Period:
1995-1998
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Awards:
No specific widely publicized awards for the SZR660 model itself; appreciated within its segment for its character.
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