Yamaha SZR 660 1995 Workshop Service Repair Manual

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Type: Motorcycle

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Sku: 142836

Tags: 1995 Motorcycle Motorcycles SZR 660 SZR Models Yamaha

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Description

The Yamaha SZR 660, produced in 1995, is a performance-oriented middleweight sport motorcycle designed to offer accessible performance and nimble handling. This model represents Yamaha's commitment to engineering quality and innovation in the sportbike segment, providing a capable alternative to larger displacement machines of its era. With its single-cylinder, liquid-cooled 660cc engine, the SZR 660 delivers a balanced blend of power and user-friendliness, making it suitable for both experienced riders and those looking to step into the sportbike category. Its design philosophy emphasizes a stable and predictable riding experience, reflecting Yamaha's heritage of building reliable and enjoyable motorcycles. This comprehensive workshop service and repair manual covers the Yamaha SZR 660 (1995) in detail, providing essential information for maintenance, diagnostics, and repair. Within its 207 pages, you will find in-depth coverage of all major systems, including the engine, fuel system, braking system, suspension, and electrical system. The manual outlines routine maintenance procedures, troubleshooting guides for common issues, and step-by-step repair instructions. It is an invaluable resource for owners and technicians alike, offering the technical specifications, diagrams, and illustrations necessary to keep the SZR 660 in optimal condition and ensure its longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SZR 660

Year:

Vehicle Type:

Sport Motorcycle

Codes

Chassis Code:

4SU1 (likely, based on typical Yamaha designations for this era)

👋 Introduction

Market Position

Positioning:

Performance-oriented middleweight sportbike, positioned as a more accessible alternative to larger displacement sportbikes of its era.

Competitive Analysis

Competitors:

Competed against other 600cc class sportbikes and performance-oriented motorcycles from manufacturers like Honda, Kawasaki, Suzuki, and Ducati.

Key Features

Engine Type:

Single-cylinder, four-stroke, liquid-cooled, DOHC

Design Philosophy:

Focus on nimble handling and accessible performance for a wide range of riders.

📋 Manual Details

Coverage Areas

Primary Focus:

Workshop Service & Repair

Secondary Focus:

Maintenance, Diagnostics, Troubleshooting, Electrical Systems

Page Count

Number Of Pages:

Manual Type

Type:

Factory Original Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

Compatibility:

All Versions of Windows & Mac

Reader Requirement:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine:

Complete Engine Overhaul, Assembly, Disassembly, Carburetor, Valves, Ignition, Lubrication

Power Supply:

Charging System, Battery, Alternator, Starter Motor

Cooling System:

Radiator, Fan, Hoses, Thermostat, Coolant Specifications

Fuel System:

Fuel Tank, Fuel Pump, Fuel Lines, Carburetor Tuning and Servicing (Mikuni BST34 Twin Carburetors)

Braking System:

Front and Rear Brake Calipers, Master Cylinders, Brake Lines, Pads, Fluid Specifications, Bleeding Procedures

Suspensions:

Front Forks (Oil Level, Seals, Spring Preload), Rear Shock Absorber (Adjustments, Rebuild)

Chassis:

Frame, Swingarm, Bearings, Fasteners, General Chassis Inspection

Electrical System:

Wiring Diagrams, Lighting System, Ignition System, Battery Charging, Horn, Switches, Fuses, Indicators

Bodywork:

Fairings, Seat, Fuel Tank Cover, Fenders, Component Removal and Installation

Procedures Included

Maintenance:

Regular Service Checks, Lubrication Points, Filter Replacements, Spark Plug Replacement, Chain Adjustment

Troubleshooting:

Systematic Diagnostic Procedures for Common Problems, Fault Finding Guides

Repair:

Detailed Step-by-Step Repair Instructions for all Major Components

Diagnostics:

Diagnostic Flowcharts and Procedures for Identifying Issues

Special Tools:

Identification and Usage of Specific Tools Required for Servicing

Technical Depth

Depth:

Comprehensive, Suitable for Professional Technicians and Advanced DIY Mechanics

📊 Manual Specifications

File Format

Searchability:

Likely Searchable Text within PDF (depending on original scanning quality)

Print Quality

Quality:

High-Resolution Scans of Original Factory Documentation, Includes Diagrams and Illustrations

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4BP (typical for the 3LD/3TB engine family)

Displacement:

660 cc

Bore X Stroke:

100 mm x 84 mm

Compression Ratio:

9.7:1

Valve Train:

DOHC, 4 valves per cylinder

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approximately 48-50 HP (claimed)

Torque:

Approximately 57 Nm (claimed)

Fuel System

Carburetion:

Twin Mikuni BST34 CV carburetors

Fuel Type:

Unleaded gasoline

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Lubrication

Lubrication System:

Wet Sump

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approximately 2100 mm

Width:

Approximately 730 mm

Height:

Approximately 1170 mm

Wheelbase:

Approximately 1420 mm

Weights

Dry Weight:

Approximately 168 kg

Wet Weight:

Approximately 182 kg (fully fueled and ready to ride)

Fuel Tank Capacity:

15 Liters

Wheels Tires

Front Tire:

120/70ZR17

Rear Tire:

160/60ZR17

Front Wheel:

17-inch

Rear Wheel:

17-inch

🛡️ Safety Features

Ratings

Crash Safety:

Not Applicable (Motorcycle; safety focus on rider protection and bike stability)

Active Features

Braking:

Disc brakes front and rear

Passive Features

Chassis Design:

Stable and predictable handling characteristics

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Assistance Features:

N/A (No electronic rider aids like ABS or traction control)

Connectivity

Connectivity:

Instrumentation

Instrument Cluster:

Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km or 6 months, refer to manual for specifics.

Air Filter Cleaning Replacement:

Check every 6,000 km, clean or replace as needed.

Spark Plug Replacement:

Typically every 10,000-15,000 km, check manual for exact type and gap.

Chain Maintenance:

Lubricate and adjust chain every 1,000 km or after riding in wet conditions.

Fluid Specifications

Engine Oil Type:

API SG, JASO MA certified 10W-40 or 20W-50 (refer to manual for precise recommendation)

Engine Oil Capacity:

Approximately 2.4 Liters (without filter change), 2.6 Liters (with filter change)

Coolant Type:

Ethylene glycol-based antifreeze coolant (50% mixture with distilled water)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Carburetor synchronization and jetting, clutch wear, fork seals, exhaust system corrosion, potential electrical connector issues.

Single Cylinder Characteristics:

Higher vibration levels than multi-cylinder bikes, which can lead to loosening of fasteners over time if not properly maintained.

📚 Vehicle History

Brand Heritage

Heritage:

Yamaha Corporation is a Japanese multinational corporation known for its wide range of products, including motorcycles, musical instruments, and power equipment. Yamaha motorcycles have a long history of performance and innovation.

Model Evolution

Predecessors:

The SZR 660 drew inspiration from Yamaha's successful single-cylinder models and was part of the evolution of sportbike design, adapting to the demand for accessible performance.

Lineage:

Shared engine technology with other Yamaha models like the TDM and XTZ series (though often in different states of tune).

Production

Production Years:

Produced from the early to mid-1990s, with the 1995 model being a key representation of this generation.

Manufacturing Location:

Japan (typical for Yamaha motorcycles of this era)

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Specific awards for the SZR 660 are not widely documented, but Yamaha's reputation for producing reliable and capable motorcycles is a testament to their engineering.