The Yamaha SZR660 is a motorcycle model from 1998, recognized for its lightweight, agile, and track-focused performance within its displacement class. Built upon Yamaha's legacy of innovation and engineering prowess, the SZR660 features a liquid-cooled, single-cylinder, 4-stroke engine, typically around 660cc, delivering an estimated 50-60 horsepower. Its design philosophy emphasizes nimble handling, further enhanced by a steel perimeter frame, telescopic front forks, and a linkage-assisted monoshock rear suspension. The braking system utilizes dual front discs and a single rear disc for effective stopping power, contributing to its safety and performance capabilities.
This digital factory service repair manual provides comprehensive guidance for the maintenance and repair of the Yamaha SZR660. It covers a wide array of systems, including general information, technical specifications, periodic inspections and adjustments, engine overhaul, cooling system, carburetor, chassis, and electricals, along with troubleshooting procedures. The manual is designed to empower owners and technicians by offering detailed information on engine rebuilds, carburetor tuning, chassis component replacement, and systematic diagnostic approaches for common and complex issues, ensuring the longevity and optimal performance of the vehicle.
Segment:
Performance Lightweight Sportbike
Competitors 1998:
Honda CBR250RR, Kawasaki ZXR250, Suzuki GSX-R250 (regional variations apply)
Design Philosophy:
Lightweight, agile, track-focused performance for its displacement class.
Purpose:
Empower owners and technicians with comprehensive knowledge for maintenance and repair.
Primary Focus:
Service and Repair
Systems Covered:
General Information, Technical Specifications, Periodic Inspections and Adjustment, Engine Overhaul, Cooling System, Carburetor, Chassis, Electricals, Troubleshooting
Estimated Count:
Variable (Digital, comprehensive)
Type:
Digital Factory Service Repair Manual
Primary Language:
English
Accessibility:
Usable on Windows, Mac, Smartphones, Tablets
Viewing Requirements:
Adobe PDF Reader, WinZip for extraction
Engine:
Detailed overhaul, inspection, adjustment, troubleshooting
Cooling System:
Components, maintenance, troubleshooting
Fuel System:
Carburetor service, adjustment, troubleshooting
Chassis:
Suspension, steering, brakes, wheels, frame components
Electrical System:
Wiring diagrams, components, ignition, lighting, starting system
Maintenance:
Periodic inspections, adjustments, lubrication
Repair:
Engine rebuild, carburetor tuning, chassis component replacement
Troubleshooting:
Systematic diagnostic procedures for common and complex issues
Depth:
Comprehensive, suitable for both novice and experienced technicians
Searchability:
Likely searchable text within PDF
Quality:
Digital, resolution dependent on original source
Configuration:
Single-cylinder, 4-stroke
Displacement:
660cc (approximate, based on model variants and market specifications)
Cooling System Type:
Liquid-cooled
Horsepower Estimated:
50-60 HP (estimated, actual varies by region and specific tuning)
Torque Estimated:
45-55 Nm (estimated)
Induction:
Carburetor (likely Mikuni VM series or similar)
Fuel Type:
Unleaded Gasoline
System Type:
Digital CDI (Capacitor Discharge Ignition)
Components:
Cylinder head, piston, crankshaft, connecting rod, valve train, gearbox.
Type:
Constant Mesh, 6-speed
Clutch Type:
Wet, multi-plate
Specification:
Yamaha Genuine Oil 10W-40 or equivalent motorcycle-specific API SE, SF, SG, SH, SJ
Capacity Engine Oil Change:
Approx. 2.0 - 2.2 Liters (check manual for exact quantity)
Length Approx:
2050 mm (example)
Width Approx:
720 mm (example)
Height Approx:
1130 mm (example)
Dry Weight Approx:
170 kg (example)
Frame:
Steel Perimeter Frame
Type:
Telescopic fork, adjustable preload (often)
Type:
Monoshock, linkage-assisted, adjustable preload and rebound damping (often)
Type:
Dual Disc, hydraulic
Type:
Single Disc, hydraulic
Safety Standards:
Compliance with relevant national and international motorcycle safety regulations for 1998.
Braking System:
Powerful dual front disc and single rear disc brake setup for effective stopping power.
Lighting System:
Comprehensive lighting including headlight, taillight, brake light, and turn signals for visibility.
Features:
N/A (Motorcycle of this era focuses on core performance rather than infotainment systems).
Features:
N/A (Motorcycle of this era focuses on rider skill rather than electronic rider aids).
Engine Management:
Advanced for its time, likely featuring digital ignition timing for optimal performance and emissions.
Oil Change:
Every 4,000 - 6,000 km or annually, whichever comes first (refer to manual for exact recommendation).
Spark Plug Replacement:
Every 10,000 - 12,000 km (refer to manual for specific plug type and gap).
Air Filter Cleaning:
Every 4,000 - 8,000 km or as needed based on operating conditions.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Carburetor Tuning:
Sensitivity to altitude and temperature changes requiring occasional recalibration.
Electrical Connections:
Potential for corrosion or loosening of electrical connectors over time, impacting system reliability.
Maintenance Tasks Covered
Specific Tasks:
Valve clearance adjustment, carburetor synchronization, chain adjustment, brake pad inspection/replacement.
Yamaha Legacy:
Yamaha Motor Company is renowned for its innovation in motorcycle design, performance, and engineering, with a strong racing pedigree.
Szr Lineage:
The SZR series represented Yamaha's effort to offer accessible, sporty performance in the middleweight category, often leveraging advanced engine technology.
Manufacturing Location:
Primarily Japan (though specific assembly locations could vary by market).
Award Status:
Specific awards for the 1998 SZR660 are not widely documented, but the model was generally well-regarded for its handling and performance in its class.
