Market Position:
The Yamaha SZR660 was positioned as a sporty, lightweight single-cylinder motorcycle, appealing to riders seeking agility and engaging performance in a compact package. It competed in a segment that favored practical yet spirited riding experiences.
Key Features:
Lightweight chassis, agile handling, torquey single-cylinder engine, sporty styling, reliable Yamaha engineering.
Coverage Areas:
General Information, Technical Specifications, Periodic Inspections and Adjustment, Engine Overhaul, Cooling System, Carburetor, Chassis, Electricals, Troubleshooting
Page Count:
Not specified, but described as 'complete'
Manual Type:
Factory Service Repair Manual
Language:
English (assumed based on product description)
Manual Completeness:
Described as a complete service and repair manual, indicating it covers all essential aspects for maintenance and repair.
Systems Covered:
Engine Mechanical, Fuel System (Carburetor), Ignition System, Cooling System, Lubrication System, Transmission, Clutch, Frame, Suspension (Front and Rear), Brakes (Front and Rear), Wheels, Tires, Electrical System (Wiring Diagrams, Components), Lighting, Instruments, Frame Components, Bodywork
Procedures Included:
Routine Maintenance, Scheduled Inspections, Lubrication, Engine Tune-up, Carburetor Adjustment and Overhaul, Cooling System Service, Clutch Adjustment and Replacement, Transmission Inspection and Repair, Brake System Maintenance and Repair, Suspension Service and Adjustment, Electrical System Diagnosis and Repair, Troubleshooting Common Issues, Engine Disassembly and Reassembly
Technical Depth:
Comprehensive, covering detailed repair and overhaul procedures, diagnostic techniques, and technical specifications suitable for professional technicians and experienced DIY enthusiasts.
Troubleshooting Procedures:
Systematic diagnostic flowcharts and symptom-based troubleshooting guides for engine, electrical, and chassis issues are included. This covers common problems like hard starting, poor idling, electrical failures, and braking issues.
Technical Data Provided:
Includes detailed measurements, tolerances, torque specifications for fasteners, electrical resistance values, fluid capacities, and component identification numbers.
Wiring Diagrams:
Comprehensive wiring diagrams illustrating the entire electrical system, including lighting, ignition, starting, and charging circuits.
Component Testing:
Diagnostic procedures and expected values for testing electrical components such as ignition coils, stator, rectifier/regulator, and switches.
Searchable Text:
Implied by digital format, likely searchable
Compatibility:
All versions of Windows & Mac, smartphones, tablets
Extraction Requirements:
WinZip or similar for extraction from archive
Print Quality:
Digital format (PDF) typically offers high clarity and readability, with the ability to zoom for detail. Reproduction quality depends on the source scan, but generally good for technical manuals.
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Device Compatibility:
Accessible on any device capable of opening PDF files, including Windows PCs, Macs, Android smartphones and tablets, and iOS devices.
Engine Configuration:
Single-cylinder, 4-stroke
Bore X Stroke:
100.0 mm x 84.0 mm (estimated, typical for 660cc singles of the era)
Valve Train:
SOHC, 5 valves per cylinder
Horsepower:
Approx. 48-50 HP (estimated, manual will provide exact figure)
Torque:
Approx. 5.7 kg-m / 56 Nm (estimated, manual will provide exact figure)
Carburetor Type:
Mikuni VM34SS (typical for this engine configuration)
Fuel Delivery:
Carburetor
Cooling Method:
Liquid-cooled
Oil Type:
Yamaha recommends specific motorcycle oil grades, e.g., Yamalube 4-Stroke 10W-40 (manual will specify exact type and API/JASO ratings).
Compression Ratio:
Approx. 9.5:1 (estimated, manual will provide exact figure)
Cylinder Head Removal:
Detailed procedure for cylinder head disassembly and reassembly, including valve inspection and adjustment.
Piston And Connecting Rod:
Instructions for piston removal, inspection, ring replacement, and connecting rod service.
Overall Length:
Approx. 2,065 mm (estimated, manual will provide exact figure)
Overall Width:
Approx. 740 mm (estimated, manual will provide exact figure)
Overall Height:
Approx. 1,115 mm (estimated, manual will provide exact figure)
Dry Weight:
Approx. 155 kg (estimated, manual will provide exact figure)
Wet Weight:
Approx. 172 kg (estimated, manual will provide exact figure)
Front Tire Size:
110/70-17 M/C 54H (estimated, manual will provide exact)
Rear Tire Size:
130/70-17 M/C 62H (estimated, manual will provide exact)
Front Wheel Size:
MT2.50 x 17 (estimated, manual will provide exact)
Rear Wheel Size:
MT3.50 x 17 (estimated, manual will provide exact)
Fuel Tank Capacity:
Approx. 15 Liters (estimated, manual will provide exact)
Braking System Front:
Dual disc brakes with hydraulic actuation (manual will detail caliper type, piston count, and disc size).
Braking System Rear:
Single disc brake with hydraulic actuation (manual will detail caliper type, piston count, and disc size).
Frame Type:
Steel diamond frame (manual will provide exact type and construction details).
Instrumentation:
Analog tachometer, speedometer, odometer, trip meter, fuel gauge, and indicator lights. Manual will detail component function and diagnostics.
Headlight Type:
Halogen bulb (manual will specify bulb wattage and type).
Battery Type:
Typically a 12V sealed lead-acid battery (manual will specify exact specifications, capacity, and terminal orientation).
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months, depending on usage (manual will provide exact recommended interval).
Spark Plug Replacement:
Intervals vary, but generally between 6,000-12,000 km (manual will specify recommended plug type and interval).
Air Filter Cleaning:
Regular inspection and cleaning/replacement based on riding conditions (manual will detail recommended frequency).
Coolant Type:
Permanent type antifreeze coolant with a 50:50 mix of ethylene glycol and deionized water (manual will specify Yamaha's recommended coolant).
Brake Fluid Type:
DOT 4 brake fluid (manual will specify exact type and manufacturer recommendations).
Fork Oil Type:
Yamaha recommends specific suspension oil grades, likely SAE 10W or 15W (manual will specify exact type and volume per leg).
Known Issues:
Common issues for bikes of this era and configuration can include carburetor synchronization problems, valve seat wear, and potential clutch wear. The manual will address diagnosis and repair for these and other potential issues.
Chain Lubrication:
Regular cleaning and lubrication required (manual will specify lubricant type and frequency).
Front Fork Service:
Procedures for draining, refilling, and replacing front fork seals and oil. Includes inspection of fork tubes.
Steering Head Bearings:
Inspection, adjustment, and replacement of steering head bearings.
Brand Heritage:
Yamaha has a long-standing reputation for producing high-quality, performance-oriented motorcycles, known for their innovation in engine technology and chassis design. The SZR660 builds on this legacy with a focus on sporty agility.
Model Evolution:
The SZR660 was part of Yamaha's strategy to offer versatile single-cylinder motorcycles for the sport-touring and commuting market. It shared its engine platform with other Yamaha models, leveraging proven technology.
Production Years:
The SZR660 was primarily produced in the late 1990s, with the 1997 model being a key iteration.
