User Manuals: Yamaha SZR 660 Sport Motorcycle

User Manuals: Yamaha SZR 660 Sport Motorcycle

Manuals and User Guides for Yamaha SZR 660 Sport Motorcycle. We have 1 Yamaha SZR 660 Sport Motorcycle manual available for free PDF download: Service Manual

Yamaha SZR 660 Service Manual

Yamaha SZR 660 Service Manual (208 pages)

Brand: Yamaha | Category: Motorcycle | Size: 36 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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