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Manuals
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Yamaha Manuals
Motorcycle
SZR 660
Service manual
Yamaha SZR 660 Service Manual
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Table Of Contents
208
page
of
208
Go
/
208
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Warning
Format
Particularly Important Information
Layout
Contents
Symbol Legend
General Information
Identification of Motorcycle
Identification Number
Engine Serial Number
Preparation for Disassembly and Reassembly
Circlips
Bearings and Oil Seals
Gaskets, Oil Seals and O-Rings
Spare Parts
Special Tools
Table of Contents
Technical Specifications
General Specifications
Maintenance Specifications
Electric System
Chassis
Tightening Torques
Maintenance Specifications
Tightening Sequence
Definition of Units of Measurement
General Specifications about Tightening Torques
Lubrication Circuit
Cooling Layout
Cable Routing
Periodic Inspection and Adjustment
Maintenance/Lubrication Intervals
Job Instruction Chart
Seat, Fuel Tank and Rear Cowling
Cowling
Engine
Valve Clearance Adjustment
Drive Chain Adjustment
Idle Speed Adjustment
Spark Plug Inspection
Throttle Cable Free Play Adjustment
Ignition Timing Check
Compression Inspection
Engine Oil Level Check
Engine Oil Replacement
Cable Free Play Adjustment
Clutch Adjustment
Engine Oil Pressure Check
Air Filter Cleaning
Suction Hose and Manifold Inspection
Checking the Coolant Level
Crankcase Ventilation Hose Inspection
Exhaust System Inspection
Fuel Line Inspection
Changing the Coolant
Cooling Circuit Inspection
Chassis
Front Brake Adjustment
Rear Brake Adjustment
Brake Fluid Level Check
Brake Hosing Inspection
Brake Pad Wear Inspection
Brake Circuit Bleeding
Drive Chain Tightness Inspection and Adjustment
Drive Chain Lubrication
Front Fork Inspection and Adjustment
Compression Damping Effect Adjustment
Shock Absorber Inspection and Adjustment
Spring Length with Preload
Spring Preload Adjustment
Extension Damping Effect Adjustment
Steering Inspection
Tyre Inspection
Cable Inspection and Lubrication
Lever and Pedal Lubrication
Swing Arm Lubrication
Wheel Inspection
Fuse Inspection and Replacement
Vertical Setting of the Headlight Beam
Battery Inspection
Charging Method
Battery Condition Check Stages
Method for Charging with a Variable Battery Charger
Method for Charging with a Constand Current Battery Charger
Engine Overhaul
Battery Cables
Cooling Circuit
Engine Oil
Engine Removal
Air Filter Case and Carburetor
Clutch Cable
Drive Chain
Exhaust Pipe
Engine Detachment
Cylinder Head, Cylinder and Piston
Engine Disassembly
Starter Motor and Hoses
Rotor and Starter Drivers
Clutch and Balancer Gear
Crankcase (Right)
Balancer, Transmission and Shifter
Oil Strainer
Crankshaft
Rocker Arm
Valves
Cylinder Head
Inspection and Repair
Valves and Valve Guides
Valve Housing
Camshaft
Valve Spring
Decompression
Rocker Arm and Rocker Arm Shaft
Camshaft Chain Guide
Cylinder and Piston
Piston Rings
Piston Pin
Balancer Drive Gear and Balancer Gear
Clutch
Primary Drive
Transmission and Gearbox
Bearing and Oil Seal
Crankcase
Oil Delivery Pipes
Oil Pump, Water Pump and Strainer
Engine Assembly and Setting
Valves and Rocker Arms
Rocker Arms
Balancer Shaft and Transmission
Shifteer
Engine Oil Pump Suction
Shift Lever and Oil Pump
Balancer Shaft Gear
Starter Gears and Rotor
Cylinder
Camshaft and Camshaft Chain
Cylinder Head and Cylinder Piston
Pipes and Hoses
Engine Reassembly
Cooling System
Cooling System
Radiator
Assembly
Inspection
Job Instruction Chart
Thermostat
Water Pump
Assembly
Carburetor
Carburetor
Section View
Removal
Primary Carburetor
Assembly
Disassembly
Installation
Checking the Pump Operation
Fuel Level Adjustment
Fuel Pump
Inspection
Installation
Removal
Front Wheel
Removal
Inspection
Static Balancing
Rear Wheel
Inspection
Removal of Rear Wheel
Front and Rear Brake
Front Brake Caliper
Front Master Cylinder
Rear Brake Caliper
Rear Master Cylinder
Brake Pad Replacement
Front Brake Caliper Disassembly
Removal and Disassembling of Front Brake Caliper
Rear Brake Caliper Disassembly
Front Master Cylinder Disassembly
Rear Master Cylinder Disassembly
Inspection and Repair
Front Fork
Removal of Front Fork
Oil Change
Topping up Procedure
Cleaning the Dust Seal
Dust Seal Cleaning
Dust Seal Remounting
Replacing Seals and Bushes
Dust Seal Dismounting
Sequence of du Bush Assembly
Oil and Mounting Sequence
Mounting Procedure
Adjusting the Compression Damping Effect
Adjusting the Rebound Damping Effect
Adjustment
Steering Removal
Bearings
Inspection
Installation
Removal
Steering Axle
Note on Disposal
Rear Shock Absorber Removal
Adjustment
Before Neutralising the Rear Shock Absorber
Note on Disposal
Swing Arm
Removal of Swing Arm
Drive Chain, Sprocket and Crown Wheel Removal
Electricals
Colour Code
Electrical Circuit Diagram
Electrical Components
Main Switch Inspection
Switch Check
Switch Connection
Bulb Inspection
Bulb Types
Ignition System Circuit Diagram
Diagnostics
If the Ignition System Stop Working
Electrical Starting System Circuit Diagram
Diagnostics
Starter Circuit Functioning
The Starte Fails to Work
Starter Motor
How to Inspect the Excitation Coils
Charging System Circuit Diagram
Diagnostics
The Battery Cannot be Charged
Light System
Diagnostics
Signalling System Circuit Diagram
Diagnostics
Signalling System Control
Cooling System Circuit Diagram
Diagnostics
Electrical System Diagram
Troubleshooting
Failure to Start/Difficulties in Starting
Fuel System
Difficulties in Changing Gear
Electrical System
Gear Change Impossible
Poor Performance at Idle Speed
Unsatisfactory Performance at Medium-High Speed
Clutch Slides
Excessive Engine Cooling
Overheating of Engine
Defective Brakes
Oil Leaks or Malfunctioning of Front Fork
Poor Braking
Unstable Steering
Defective Functioning of Lights and Indicators
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General Specifications
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Electric System
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Enlarged version
YAMAHA
4SU-ME1
SERVICE
SZR660('95)
SERVICE
MANUAL
©1996BELGARDAS.p.A.
R&D
TECHNICAL
DIVISION
V*
edition
February 1996
All
rights
reserved.
Any
reprinting or
unauthorised use
without
the written
permission
ol
Belgarda
S.p.A,
is
expressly
prohibited.
Although
some
of the
drawings
and
photographs
used
in this
manual
are taken from
other
manuals
and
do
not
refer directly to
the
mode?
in
question,
me
procedures described
and
the
details illustrated
are nonetheless
relevant
and
suitable to
the user's purposes.
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