Market Segment:
Lightweight sportbike/supermoto segment, often popular for its agility and unique styling.
Key Competitors:
Competed against other single-cylinder 600-660cc class bikes from manufacturers like Suzuki (e.g., early SV650 variants), Aprilia, and some Italian brands, as well as some performance-oriented dual-sport or supermoto conversions.
Distinctive Attributes:
The SZR660 was notable for its single-cylinder engine derived from Yamaha's XT660 platform, often housed in a sporty chassis. It offered a torquey power delivery and a focused riding experience, distinguishing it from multi-cylinder sportbikes of the era.
Coverage Scope:
All repairs covered A-Z, all models 1995-1998
Page Count:
Not explicitly stated, but implied to be comprehensive
Manual Type:
Service Repair Workshop Manual
Language:
English (implied by product description)
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor specifics, fuel pump), ignition system, exhaust system.
Drivetrain Systems:
Transmission (gearbox internals, clutch operation, lubrication), final drive (chain and sprocket maintenance).
Chassis Systems:
Frame inspection and repair, suspension (front fork service, rear shock absorber), steering system (handlebar, triple clamps), braking system (hydraulic circuits, caliper overhaul, pad replacement, disc maintenance), wheel and tire service.
Electrical Systems:
Wiring diagrams, lighting system (headlight, taillight, indicators), charging system (stator, rectifier/regulator, battery), starting system (starter motor, solenoid), ignition control unit (CDI).
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank mounting, fender service.
Maintenance Procedures:
Routine checks (oil level, coolant, tire pressure), lubrication points, chain adjustment, filter replacements, spark plug service, valve clearance adjustment.
Troubleshooting Guides:
Diagnostic charts for common starting, running, and electrical issues.
Repair And Rebuild Procedures:
Detailed step-by-step instructions for engine rebuilds, carburetor overhaul, brake system bleeding, fork seal replacement, and more.
Special Tool Requirements:
Identification of specific tools needed for certain procedures (e.g., torque wrenches, specialized engine tools).
Depth Of Information:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed specifications, tolerances, and diagnostic procedures.
Engine Displacement:
660cc
Engine Configuration:
Single-cylinder, 4-stroke, SOHC, 4 valves per cylinder
Bore X Stroke:
Approximately 100 mm x 84 mm (based on XT660 engine family)
Compression Ratio:
Likely around 9.2:1 to 9.7:1 (depending on specific market tune)
Cooling System:
Liquid-cooled
Horsepower Output:
Approximately 45-50 HP (Varies by market and tuning)
Torque Output:
Approximately 5.5-6.0 kgf-m or 40-43 lb-ft (Varies by market)
Carburetor Type:
Likely a Mikuni BST34 or similar downdraft carburetor
Fuel Tank Capacity:
Around 15-16 Liters
Oil Type Specification:
Yamaha recommends Yamalube 4 (or equivalent API SG, SAE 20W-40 or 10W-30)
Oil Capacity With Filter:
Approximately 2.0 - 2.2 Liters
Safety Certifications:
Meets relevant national and international road safety standards for motorcycles of its class.
Braking System:
Hydraulic front disc brake (likely 2-piston caliper), Hydraulic rear disc brake (likely single-piston caliper).
Suspension Geometry:
Designed for agility and stability, contributing to safe handling characteristics.
Oil Change Interval:
Every 3,000-5,000 km or 6 months, whichever comes first (refer to manual for exact specifications).
Air Filter Service:
Inspect every 5,000 km, clean or replace as needed.
Spark Plug Replacement:
Recommended every 10,000-15,000 km (specific plug type and gap critical).
Valve Clearance Adjustment:
Typically every 10,000-20,000 km, or as indicated by engine noise (critical for performance and longevity).
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for specific recommendation, always use fresh fluid).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Common Wear Items:
Clutch wear, carburetor jetting/cleaning requirements due to fuel quality variations, front fork seal leaks, potential voltage regulator issues common on older Yamahas.
Carburetor Idiosyncrasies:
Sensitivity to atmospheric conditions and fuel quality; requires periodic cleaning and precise adjustment for optimal performance.
Yamaha Motorcycles:
Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, known for innovation and performance across various segments, from sportbikes to off-road and cruisers.
Szr Development:
The SZR660 was part of Yamaha's strategy to offer unique, lighter-weight, single-cylinder performance bikes that appealed to riders seeking maneuverability and character. It leveraged proven engine technology from their dual-sport line.
Production Years:
1995-1998 (as per manual coverage)
Manufacturing Location:
Primarily Japan, with potential assembly in other regions.
Motorcycle Awards:
Specific awards for the SZR660 are not widely documented, but it was recognized within its niche for its unique character and agile handling.
Performance Reviews:
Contemporary reviews highlighted its lively engine, capable chassis, and fun factor, especially in urban or twisty road environments.
