Segment:
Sportbike/Naked Bike segment, targeted at riders seeking a capable and relatively lightweight performance motorcycle.
Competitors 1999:
Competed with models like the Suzuki SV650, Kawasaki ER-5, Honda CB500, and Ducati Monster series in various markets.
Engine Configuration:
Single-cylinder, liquid-cooled engine known for its torquey delivery.
Design Philosophy:
Emphasis on a manageable power delivery and agile handling, making it suitable for both spirited riding and everyday commuting.
Systems Covered:
General Information, Technical Specifications, Periodic Inspections and Adjustment, Engine Overhaul, Cooling System, Carburetor, Chassis, Electricals, Troubleshooting
Estimated Page Count:
Likely 200-400 pages (typical for this era of motorcycle service manual)
Type:
Factory Service Repair Manual
Language:
English (assumed, common for factory manuals)
Engine:
Complete overhaul procedures, valve clearance adjustment, piston and ring replacement, crankshaft and connecting rod inspection/replacement, timing chain and sprockets, lubrication system.
Cooling System:
Radiator, coolant, water pump, thermostat, hoses, and related components diagnosis and repair.
Fuel System:
Carburetor (Mikuni VM series likely) dismantling, cleaning, adjustment, jetting, float level setting, fuel tank, fuel lines, and fuel petcock.
Chassis:
Frame inspection, front fork overhaul (oil, seals, springs), rear shock absorber inspection/replacement, swingarm maintenance, wheel bearing service, steering head bearing adjustment.
Electricals:
Wiring diagrams, ignition system (CDI, spark plugs), lighting (headlight, taillight, signals), battery, starter motor, charging system (alternator/stator, regulator/rectifier), instrumentation, horn.
Brakes:
Front and rear brake system inspection, hydraulic fluid replacement, caliper overhaul, pad replacement, disc inspection, brake line maintenance.
Maintenance:
Routine checks, lubrication points, filter replacement, spark plug replacement, chain adjustment, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, fault diagnosis trees, symptom-based troubleshooting for engine, electrical, and chassis issues.
Rebuilds:
Comprehensive step-by-step instructions for engine overhaul and major component repairs.
Depth:
Factory-level diagnostic and repair information, suitable for experienced mechanics and motivated DIY enthusiasts.
Searchability:
Likely text-searchable if the PDF was generated from a digital source or well-scanned OCR'd original.
Quality:
Digital copy, print quality depends on the original source and scanning process.
Binding:
N/A (Digital Format)
Paper:
N/A (Digital Format)
Reader:
Adobe PDF Reader or compatible PDF viewer.
Extraction:
Standard file extraction utility for .zip archives.
Device Compatibility:
Compatible with Windows and macOS; viewable on smartphones and tablets with PDF reader applications.
Engine Type:
4-stroke, SOHC, 4-valve, Single Cylinder
Displacement:
660 cc (Actual displacement may vary slightly based on market, but 660cc is the common designation for the SZR660 engine family)
Bore X Stroke:
Typically around 100 mm x 84 mm (specific figures to be confirmed in manual)
Compression Ratio:
Likely in the range of 9.5:1 to 10.5:1 (specific figures to be confirmed in manual)
Horsepower:
Estimated 48-55 HP at RPM (specific figures to be confirmed in manual)
Torque:
Estimated 50-55 Nm at RPM (specific figures to be confirmed in manual)
Carburetor Type:
Single Mikuni VM Series carburetor (e.g., VM36 or VM38), or similar downdraft type. Specific model number required from manual.
Fuel Type:
Unleaded gasoline, minimum octane rating of 91 (RON+MON)/2 (equivalent to 87 AKI in North America)
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic advance.
Oil Type:
API SG or higher, JASO MA certified motorcycle oil. Viscosity typically 10W-40 or 20W-50 depending on climate. Exact specification in manual.
Oil Capacity:
Approximately 2.0-2.5 liters with filter change. Exact capacity in manual.
Cooling Method:
Liquid-cooled.
Coolant Type:
Ethylene glycol-based antifreeze and water mixture (50/50 ratio recommended). Specific type and capacity in manual.
Transmission Type:
Constant mesh 5-speed sequential gearbox.
Clutch Type:
Wet, multi-plate clutch, cable-operated.
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning.
Transmission Oil Type:
Engine oil is typically used for the transmission in this configuration. Refer to manual for specific recommendations.
Overall Length:
Refer to manual for exact dimensions.
Overall Width:
Refer to manual for exact dimensions.
Seat Height:
Refer to manual for exact dimensions.
Dry Weight:
Approximately 150-160 kg (specific weight to be confirmed in manual).
Wet Weight:
Approximately 165-175 kg (with all fluids, specific weight to be confirmed in manual).
Fuel Tank Capacity:
Approximately 15-17 liters (specific capacity to be confirmed in manual).
Safety Features Notes:
As a motorcycle, safety is heavily reliant on rider skill and protective gear. Manual will cover essential maintenance for braking and handling safety systems.
Braking System:
Front: Single Disc Brake, Rear: Single Disc Brake. Specific caliper and disc size details in manual.
Suspension Systems:
Front telescopic forks, Rear swingarm with monoshock. Tuning and maintenance procedures covered.
Instrumentation:
Analog speedometer and tachometer, odometer, trip meter, neutral indicator, high beam indicator, oil pressure warning light, turn signal indicators. Specific cluster details in manual.
Rider Aids:
None (This era of motorcycle typically did not feature electronic rider aids like ABS or traction control).
Headlight Type:
Halogen bulb (specific wattage and type in manual).
Oil Change Interval:
Typically every 3,000-5,000 km or 6 months, whichever comes first. Refer to manual for exact interval.
Spark Plug Inspection Replacement:
Inspect every 6,000-8,000 km, replace as needed. Refer to manual for exact interval and plug type (e.g., NGK CR9E or similar).
Valve Clearance Check:
Typically every 10,000-15,000 km. Crucial for engine health. Refer to manual for exact interval and specifications.
Chain Lubrication Adjustment:
Lubricate every 500-1,000 km and adjust slack as needed. Refer to manual for precise slack measurement.
Brake Fluid:
DOT 4 or DOT 5.1 recommended. Refer to manual for specific type and replacement interval.
Fork Oil:
Specific viscosity and volume (e.g., SAE 10W, ~400ml per fork leg). Refer to manual for precise specifications.
Common Wear Items:
Carburetor jets can become clogged, requiring thorough cleaning. Clutch plates can wear over time. Fork seals are prone to leakage. Electrical connections can oxidize.
Engine Characteristics:
Single-cylinder engines can vibrate more than multi-cylinder engines, which is normal but requires checking engine mounts and balance.
Yamaha Legacy:
Yamaha has a long-standing reputation for producing high-performance and reliable motorcycles, from performance sportbikes to rugged off-road machines. Known for innovation in engine technology and chassis design.
Szr Lineage:
The SZR660 was part of Yamaha's strategy to offer a capable single-cylinder sportbike, drawing on their single-cylinder engine expertise. It shared lineage with models like the XT660 and later evolved into concepts seen in other performance singles.
Production Years:
Produced in the late 1990s and early 2000s. Specific production dates for the 1999 model year.
Manufacturing Location:
Primarily manufactured in Japan.
