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Yamaha SZR 660 Manuals
Manuals and User Guides for Yamaha SZR 660. We have
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Yamaha SZR 660 manual available for free PDF download: Service Manual
Yamaha SZR 660 Service Manual (208 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 36.56 MB
Table of Contents
Warning
2
Format
2
Particularly Important Information
2
Layout
2
Contents
3
Symbol Legend
3
General Information
5
Identification of Motorcycle
6
Identification Number
6
Engine Serial Number
6
Preparation for Disassembly and Reassembly
6
Circlips
7
Bearings and Oil Seals
7
Gaskets, Oil Seals and O-Rings
7
Spare Parts
7
Special Tools
8
Table of Contents
12
Technical Specifications
12
General Specifications
13
Maintenance Specifications
15
Electric System
16
Chassis
18
Tightening Torques
19
Maintenance Specifications
21
Tightening Sequence
21
Definition of Units of Measurement
22
General Specifications about Tightening Torques
22
Lubrication Circuit
24
Cooling Layout
26
Cable Routing
27
Periodic Inspection and Adjustment
30
Maintenance/Lubrication Intervals
31
Job Instruction Chart
32
Seat, Fuel Tank and Rear Cowling
32
Cowling
33
Engine
34
Valve Clearance Adjustment
34
Drive Chain Adjustment
35
Idle Speed Adjustment
35
Spark Plug Inspection
36
Throttle Cable Free Play Adjustment
36
Ignition Timing Check
37
Compression Inspection
38
Engine Oil Level Check
39
Engine Oil Replacement
40
Cable Free Play Adjustment
42
Clutch Adjustment
42
Engine Oil Pressure Check
42
Air Filter Cleaning
43
Suction Hose and Manifold Inspection
43
Checking the Coolant Level
44
Crankcase Ventilation Hose Inspection
44
Exhaust System Inspection
44
Fuel Line Inspection
44
Changing the Coolant
45
Cooling Circuit Inspection
46
Chassis
47
Front Brake Adjustment
47
Rear Brake Adjustment
47
Brake Fluid Level Check
48
Brake Hosing Inspection
48
Brake Pad Wear Inspection
48
Brake Circuit Bleeding
49
Drive Chain Tightness Inspection and Adjustment
49
Drive Chain Lubrication
50
Front Fork Inspection and Adjustment
50
Compression Damping Effect Adjustment
51
Shock Absorber Inspection and Adjustment
51
Spring Length with Preload
51
Spring Preload Adjustment
51
Extension Damping Effect Adjustment
52
Steering Inspection
52
Tyre Inspection
53
Cable Inspection and Lubrication
54
Lever and Pedal Lubrication
54
Swing Arm Lubrication
54
Wheel Inspection
54
Fuse Inspection and Replacement
55
Vertical Setting of the Headlight Beam
55
Battery Inspection
56
Charging Method
56
Battery Condition Check Stages
57
Method for Charging with a Variable Battery Charger
58
Method for Charging with a Constand Current Battery Charger
59
Engine Overhaul
61
Battery Cables
62
Cooling Circuit
62
Engine Oil
62
Engine Removal
62
Air Filter Case and Carburetor
63
Clutch Cable
63
Drive Chain
63
Exhaust Pipe
63
Engine Detachment
64
Cylinder Head, Cylinder and Piston
65
Engine Disassembly
65
Starter Motor and Hoses
65
Rotor and Starter Drivers
67
Clutch and Balancer Gear
69
Crankcase (Right)
71
Balancer, Transmission and Shifter
72
Oil Strainer
72
Crankshaft
73
Rocker Arm
73
Valves
74
Cylinder Head
75
Inspection and Repair
75
Valves and Valve Guides
75
Valve Housing
76
Camshaft
78
Valve Spring
78
Decompression
79
Rocker Arm and Rocker Arm Shaft
79
Camshaft Chain Guide
80
Cylinder and Piston
80
Piston Rings
81
Piston Pin
82
Balancer Drive Gear and Balancer Gear
83
Clutch
83
Primary Drive
83
Transmission and Gearbox
85
Bearing and Oil Seal
86
Crankcase
86
Oil Delivery Pipes
86
Oil Pump, Water Pump and Strainer
86
Engine Assembly and Setting
87
Valves and Rocker Arms
87
Rocker Arms
88
Balancer Shaft and Transmission
90
Shifteer
90
Engine Oil Pump Suction
93
Shift Lever and Oil Pump
93
Balancer Shaft Gear
95
Starter Gears and Rotor
99
Cylinder
100
Camshaft and Camshaft Chain
101
Cylinder Head and Cylinder Piston
102
Pipes and Hoses
105
Engine Reassembly
106
Cooling System
109
Cooling System
110
Radiator
111
Assembly
114
Inspection
114
Job Instruction Chart
114
Thermostat
114
Water Pump
114
Assembly
115
Carburetor
117
Carburetor
118
Section View
118
Removal
119
Primary Carburetor
120
Assembly
122
Disassembly
122
Installation
125
Checking the Pump Operation
126
Fuel Level Adjustment
126
Fuel Pump
126
Inspection
126
Installation
126
Removal
126
Front Wheel
129
Removal
129
Inspection
130
Static Balancing
130
Rear Wheel
131
Inspection
132
Removal of Rear Wheel
132
Front and Rear Brake
133
Front Brake Caliper
133
Front Master Cylinder
133
Rear Brake Caliper
134
Rear Master Cylinder
134
Brake Pad Replacement
135
Front Brake Caliper Disassembly
137
Removal and Disassembling of Front Brake Caliper
137
Rear Brake Caliper Disassembly
138
Front Master Cylinder Disassembly
139
Rear Master Cylinder Disassembly
140
Inspection and Repair
141
Front Fork
143
Removal of Front Fork
144
Oil Change
145
Topping up Procedure
146
Cleaning the Dust Seal
147
Dust Seal Cleaning
148
Dust Seal Remounting
148
Replacing Seals and Bushes
148
Dust Seal Dismounting
150
Sequence of du Bush Assembly
151
Oil and Mounting Sequence
152
Mounting Procedure
153
Adjusting the Compression Damping Effect
154
Adjusting the Rebound Damping Effect
154
Adjustment
154
Steering Removal
155
Bearings
156
Inspection
156
Installation
156
Removal
156
Steering Axle
156
Note on Disposal
158
Rear Shock Absorber Removal
158
Adjustment
159
Before Neutralising the Rear Shock Absorber
159
Note on Disposal
159
Swing Arm
159
Removal of Swing Arm
160
Drive Chain, Sprocket and Crown Wheel Removal
162
Electricals
165
Colour Code
166
Electrical Circuit Diagram
166
Electrical Components
167
Main Switch Inspection
168
Switch Check
168
Switch Connection
168
Bulb Inspection
169
Bulb Types
169
Ignition System Circuit Diagram
170
Diagnostics
171
If the Ignition System Stop Working
171
Electrical Starting System Circuit Diagram
175
Diagnostics
176
Starter Circuit Functioning
176
The Starte Fails to Work
176
Starter Motor
179
How to Inspect the Excitation Coils
180
Charging System Circuit Diagram
182
Diagnostics
183
The Battery Cannot be Charged
183
Light System
185
Diagnostics
186
Signalling System Circuit Diagram
188
Diagnostics
189
Signalling System Control
190
Cooling System Circuit Diagram
195
Diagnostics
196
Electrical System Diagram
200
Troubleshooting
202
Failure to Start/Difficulties in Starting
203
Fuel System
203
Difficulties in Changing Gear
204
Electrical System
204
Gear Change Impossible
204
Poor Performance at Idle Speed
204
Unsatisfactory Performance at Medium-High Speed
204
Clutch Slides
205
Excessive Engine Cooling
205
Overheating of Engine
205
Defective Brakes
206
Oil Leaks or Malfunctioning of Front Fork
206
Poor Braking
206
Unstable Steering
206
Defective Functioning of Lights and Indicators
207
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