Yamaha SZR660 1995 Service & Repair Manual

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类型: Motorcycle

斯库: 156972

标签: 1995 Misc Motorcycle Motorcycles SZR660 Yamaha

产品多属性

Description

The SZR660, produced in Japan during the mid-to-late 1990s, represents a distinctive offering in the sportbike and lightweight supermoto categories. This model is characterized by its agile handling and a torquey, 659cc single-cylinder engine, a testament to heritage in performance motorcycle engineering. Designed to compete with other 600cc-class sportbikes and single-cylinder performance machines of its era, the SZR660 emphasizes a lightweight and responsive riding experience, drawing on extensive experience with performance singles and sportbike chassis development. This Service & Repair Manual provides comprehensive guidance for the SZR660, covering all aspects of its service and repair. It details routine maintenance procedures, in-depth troubleshooting, and diagnostic strategies for common issues, alongside major repair instructions and component disassembly/assembly. The manual includes essential technical specifications, wiring diagrams, and calibration details for all major systems, including the engine, fuel, ignition, cooling, transmission, suspension, brakes, and electrical systems. This resource is designed to assist owners and mechanics in effectively maintaining, diagnosing, and repairing the SZR660, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SZR660

Year:

Codes

Chassis Code:

Engine Code:

👋 Introduction

Market Position

Category:

Sportbike / Lightweight Supermoto

Target Audience:

Owners and independent mechanics of the Yamaha SZR660

Competitive Analysis

Era Competition:

Competed against other 600cc-class sportbikes and single-cylinder performance motorcycles of its time.

Key Features

Vehicle Focus:

Lightweight, agile handling, torquey single-cylinder engine

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair

Secondary Coverage:

Maintenance, troubleshooting, diagnostics

Page Count

Estimated Page Count:

Manual Type

Type:

Service & Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, component identification, performance tuning

Fuel System:

Carburetor tuning, fuel pump, fuel lines, fuel tank maintenance

Ignition System:

Spark plugs, ignition coils, CDI unit, timing adjustments

Cooling System:

Radiator, coolant, thermostat, water pump, fan operation

Exhaust System:

Muffler, exhaust pipes, catalytic converter (if applicable), gasket replacement

Transmission:

Clutch operation, gear shifting mechanisms, transmission fluid checks and changes

Suspension:

Front forks, rear shock absorber, linkage systems, spring rates, damping adjustments

Brakes:

Hydraulic system, brake pads, discs, calipers, master cylinders, bleeding procedures

Electrical System:

Wiring diagrams, battery, charging system, lighting, starter motor, fuses, relays

Chassis And Frame:

Frame inspection, steering head bearings, wheel bearings, swingarm maintenance

Bodywork And Plastics:

Fairing removal and installation, tank, seat, fender repairs

Wheels And Tires:

Tire pressure, tire wear, wheel balancing, spoke tension

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication, brake adjustments

Troubleshooting:

Diagnostic charts for common problems, symptom-based solutions

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement

Component Disassembly Assembly:

Step-by-step instructions with torque specifications

Wiring Diagrams:

Detailed electrical schematics for fault finding

Calibration And Adjustment:

Carburetor synchronization, ignition timing, suspension settings

Technical Depth

Depth:

Factory-level detail for mechanics and advanced DIY enthusiasts

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if digitally rendered correctly

Print Quality

Print Readability:

Designed for digital viewing and printing

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, liquid-cooled, DOHC, single-cylinder

Displacement:

659 cc

Bore X Stroke:

100 mm x 84 mm

Compression Ratio:

9.7:1

Performance

Horsepower Est:

~47 hp @ 6500 rpm (approximate, varies by market tuning)

Torque Est:

~55 Nm @ 5500 rpm (approximate, varies by market tuning)

Fuel System

Carburetion:

Mikuni BSR36 (single carburetor)

Fuel Type:

Unleaded gasoline

Ignition System

Ignition:

CDI (Capacitor Discharge Ignition)

Lubrication System

Oil Type Spec:

Yamalube 4 (or equivalent API SG, SAE 10W-40, JASO MA)

Cooling System

Coolant Type Spec:

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

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Final Drive:

Chain drive

Features

Gear Ratios:

Detailed ratios available within the manual

Fluid Specifications

Transmission Oil Type:

Yamalube SAE 80 GL-4 hypoid gear oil (or equivalent)

📐 Dimensions

Exterior

Length Est:

2120 mm

Width Est:

750 mm

Height Est:

1170 mm

Wheelbase Est:

1415 mm

Weights

Dry Weight Est:

170 kg

Wet Weight Est:

187 kg

Fuel Capacity:

15 Liters

Wheels And Tires

Front Tire Size:

110/70-17

Rear Tire Size:

150/70-17

Front Wheel Type:

Cast alloy

Rear Wheel Type:

Cast alloy

Wheelbase Bolt Pattern:

N/A (Spoked or Cast wheels for motorcycles)

🛡️ Safety Features

Ratings

Crash Safety Ratings:

N/A (Motorcycle safety ratings typically not applicable in the same way as cars)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Lighting:

Headlight, taillight, brake lights, turn signals

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Driver Assistance:

Connectivity

Connectivity:

Instrumentation

Instrument Cluster:

Analog speedometer, tachometer, odometer, trip meter, coolant temperature gauge, indicator lights

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 5,000 km or 6 months

Air Filter Cleaning:

Every 5,000 km

Spark Plug Replacement:

Every 10,000 km

Chain Lubrication:

Every 1,000 km or after riding in wet conditions

Brake Fluid Replacement:

Every 2 years

Fluid Specifications

Engine Oil Capacity:

2.5 Liters (without filter), 2.6 Liters (with filter)

Transmission Oil Capacity:

0.9 Liters

Coolant Capacity:

1.8 Liters

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, fork seals, carburetor jets

Potential Problems:

Carburetor gumming if left unused, charging system issues (stator/regulator)

📚 Vehicle History

Brand Heritage

Brand Focus:

Yamaha's reputation for performance motorcycles and innovative engineering.

Model Evolution

Predecessor Concept:

Draws on Yamaha's experience with performance singles and sportbike chassis.

Production

Production Years:

Mid-to-late 1990s

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

Specific awards for this model are not widely documented, but it was generally well-received for its performance in its class.