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YAMAHA SZR 660 ’95 SERVICE MANUAL – PDF DOWNLOAD
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YAMAHA SZR 660 ’95 SERVICE MANUAL – PDF DOWNLOAD
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Description
YAMAHA SZR 660 ’95 SERVICE MANUAL – PDF DOWNLOAD
DESCRIPTION:
YAMAHA SZR 660 ’95 SERVICE MANUAL – PDF DOWNLOAD
HOW TO USE THIS MANUAL
LAYOUT This manual consists of chapters on the principal cycle components (see “Symbol Legend”).
(1 }: This symbol, in the top right-hand corner of each page. identifies the chapter graphically
(2): This title appears at the top of each page to the left of the chapter symbo
(3): The final caption in the chapter “Periodic inspection and adjustment~
FORMAT
All the procedures suggested in this manual are arranged in a sequential, step by step order. The information is written in such a way as to provide the mechanic with a handy. easy to read reference containing explanations on all disassembly, repair, assembly and inspection operations. Particularly important procedure sequences (4} are shown between two rows of asterisks c·> and each procedure is preceded by the symbol” • “.
IMPORTANT SPECIFICATIONS
• All data and special tools are contained in insets preceded by the specific symbol (5)
• A number inscribed in round brackets indicates (6) the number of a part, whereas a letter of the alphabet indicates alignment data or marks (7); further indications are signalled by a letter eclosed in an inset (8).
• The condition of a faulty component precedes an arrow followed by the procedure required and the symbol (9).
ILLUSTRATED SEQUENCES
The simplest disassembly and reassembly sequences are shown in an exploded drawing of the parts and a table in which the parts themselves are numbered in progressive order of disassembly. Follow the numbers progressively to perform the disassembly sequence. Follow the numbered operations in the reverse order to perform the reassembly sequence. The table also includes notes to facilitate operations.
EXPLODED DIAGRAMS
In some chapters the disassembly section is preceded by exploded diagrams. These are designed to aid identification of components for proper assembly, as well as the assembly procedures themselves.
TABLE OF CONTENTS:
YAMAHA SZR 660 ’95 SERVICE MANUAL – PDF DOWNLOAD
Service Manual, YAMAHA SZR660........................................ 1 Warning.............................................................. 2 How to use this manual............................................... 2 CONTENTS............................................................. 3 1. General Information............................................... 4 Index............................................................ 5 Identification of Motorcycle..................................... 6 Identification Number........................................ 6 Engine serial Number......................................... 6 Important Information............................................ 6 Preparation for Disassembly and Reassembly................... 6 Spare Parts.................................................. 7 Gaskets, Oil seals and O-rings............................... 7 Lock Washers, Plates and Cotter Pins......................... 7 Bearings and Oil Seals....................................... 7 Circlips..................................................... 7 Special Tools.................................................... 7 2. Technical Specifications.......................................... 11 Index............................................................ 12 General Specifications........................................... 13 Maintenance Specifications....................................... 14 Engine....................................................... 14 Electric system.............................................. 16 Chassis...................................................... 18 Tightening Torques............................................... 19 General Torque Specifications................................ 22 Definition of Measurement units.................................. 22 Lubrication Points and Type of Lubricant......................... 23 Engine....................................................... 23 Chassis...................................................... 23 Lubrication Layout............................................... 24 Cooling Layout................................................... 26 Cable Routing.................................................... 27 3. Periodic Inspection and Adjusment................................. 29 Index............................................................ 30 Periodic Maintenance/Lubrication Intervals....................... 31 Seat, Fuel Tank and Rear Cowling................................. 32 Removal and Installation..................................... 32 Cowling.......................................................... 33 Removal and Installation..................................... 33 Engine........................................................... 34 Valve Clearance Adjustment................................... 34 Drive Chain Adjustment....................................... 35 Idle Speed Adjustment........................................ 35 Throttle Cable Free Play Adjustment.......................... 36 Spark Plug Inspection........................................ 36 Ignition Timing Check........................................ 37 Compression Inspection....................................... 38 Engine Oil Level Check....................................... 39 Engine Oil Replacement....................................... 40 Engine Oil Pressure Check.................................... 42 Clutch Adjustment............................................ 42 Air Filter Cleaning.......................................... 43 Suction Hose and Manifold Inspection......................... 43 Fuel Line Inspection......................................... 44 Crankcase Ventilation Hose Inspection........................ 44 Exhaust System Inspection.................................... 44 Checking The Coolant Level................................... 44 Changing The Coolant......................................... 45 Cooling System Inspection.................................... 46 Chassis.......................................................... 47 Front Brake Adjustment....................................... 47 Rear Brake Adjustment........................................ 47 Brake Fluid Level Check...................................... 48 Brake Pad Wear Inspection.................................... 48 Brake Hosing Inspection...................................... 48 Brake Circuit Bleeding....................................... 49 Drive Chain Tightness Inspection and Adjustment.............. 49 Drive Chain Lubrication...................................... 50 Front Fork Inspection and Adjustment......................... 50 Shock Absorber Inspection and Adjustment..................... 51 Steering Inspection.......................................... 52 Tyre Inspection.............................................. 53 Wheel Inspection............................................. 54 Cable Inspection and Lubrication............................. 54 Lever and Pedal Lubrication.................................. 54 Side Stand Lubrication....................................... 54 Rear Swing Arm Lubrication................................... 54 Electricals...................................................... 54 Headlight: Lamp Replacement and Setting...................... 54 Fuse Inspection and Replacement.............................. 55 Battery Insoection........................................... 56 4. Engine overhaul................................................... 60 Index............................................................ 61 Engine Removal................................................... 62 Cowling, Seat and Fuel Tank.................................. 62 Engine Oil................................................... 62 Cooling System............................................... 62 Battery Cables............................................... 62 Radiator..................................................... 62 Exhaust Pipe................................................. 63 Air Cleaner Case and Carburetor.............................. 63 Clutch Cable................................................. 63 Drive Chain.................................................. 63 Engine Detachment............................................ 64 Engine Diassembly................................................ 65 Starter Motor and Hoses...................................... 65 Cylinder Head, Cylinder and Piston........................... 65 Rotor and Starter Drivers.................................... 67 Oil Filter and Water Pump.................................... 68 Clutch and Balancer Gear..................................... 69 Shift Lever and Oil Pump..................................... 70 Crankcase (Right)............................................ 71 Oil Strainer................................................. 72 Balancer, Transmission and Shifter........................... 72 Crankshaft................................................... 73 Rocker Arm................................................... 73 Valves....................................................... 74 Inspection and Repair............................................ 75 Cylinder Head................................................ 75 Valves and Valve Guides...................................... 75 Valve Housing................................................ 76 Valve Spring................................................. 78 Camshaft..................................................... 78 Rocker Arms and Rocker Arm Shaft............................. 79 Camshaft Chain, Sprocket and Chain Guide..................... 79 Camshaft Chain Guide......................................... 80 Cylinder and Piston.......................................... 80 Piston Rings................................................. 81 Piston Pin................................................... 82 Crankshaft................................................... 82 Balancer Drive Gear and Balancer Gear........................ 83 Electric Starter Drive....................................... 83 Primary Drive................................................ 83 Clutch....................................................... 83 Transmission and Gearbox..................................... 85 Oil Pump, Water Pump and Strainer............................ 86 Oil Delivery Pipes........................................... 86 Crankcase.................................................... 86 Bearings and Oil Seals....................................... 86 Circlip and Washer........................................... 86 Engine Assembly and Setting...................................... 87 Valves and Rocker Arms....................................... 87 Valves....................................................... 87 Rocker Arms.................................................. 88 Crankshaft................................................... 89 Balancer Shaft and Transmission.............................. 90 Shifter...................................................... 90 Balancer, Transmission and Shifter........................... 91 Oil Strainer (exploded view)................................. 92 Crankcase (exploded view).................................... 92 Shift Lever and Oil Pump..................................... 93 Crankcase (Assembling)....................................... 93 Oil Strainer (Assembling).................................... 93 Shift Lever and Oil Pump..................................... 94 Balancer Shaft Gear.......................................... 95 Clutch....................................................... 95 Clutch and Balancer Gear..................................... 96 Oil Filter and Water Pump.................................... 98 Starter Gears................................................ 99 Cylinder.....................................................100 Cylinder Head................................................101 Camshaft and Camshaft Chain..................................101 Cylinder Head, Cylinder and Piston...........................102 Pipes and Hoses..............................................105 Engine Reassembly................................................106 5. Cooling system....................................................108 Index............................................................109 Cooling system...................................................110 Radiator.........................................................111 Job Instruction Chart........................................111 Inspection...................................................112 Assembly.....................................................112 Water Pump.......................................................113 Job Instruction Chart........................................113 Removal......................................................113 Inspection...................................................114 Assembly.....................................................114 Thermostat.......................................................114 Job Instruction Chart........................................114 Removal......................................................115 Inspection...................................................115 Assembly.....................................................115 6. Carburetor........................................................116 Index............................................................117 Carburetor.......................................................118 Technical Specifications/Tightening Torques/Exploded View....118 Section view.................................................118 Removal......................................................119 Diassembly...................................................120 Inspection...................................................121 Assembly.....................................................122 Installation.................................................125 Fuel Level Adjustment........................................125 Fuel Pump........................................................126 Checking The Pump operation..................................126 Removal......................................................126 Inspection...................................................126 Installation.................................................126 7. Chassis...........................................................127 Index............................................................128 Front Wheel......................................................129 Removal......................................................129 Inspection...................................................130 Static Balancing.............................................130 Rear Wheel.......................................................131 Removal......................................................132 Inspection...................................................132 Front and Rear Brake.............................................133 Front Master Cylinder........................................133 Front Brake Caliper..........................................133 Rear Master Cylinder.........................................134 Rear Brake Caliper...........................................134 Brake Pad Replacement........................................135 Front Brake Caliper Disassembly..............................137 Rear Brake Caliper Disassembly...............................138 Front Master Cylinder Disassembly............................139 Rear Master Cylinder Disassembly.............................140 Inspection and Repair........................................141 Front Fork.......................................................143 Removal......................................................144 Oil Change...................................................145 Cleaning the Dust seal.......................................147 Replacing the Seals and Bushes...............................148 Adjustment...................................................154 Steering.........................................................155 Removal......................................................155 Inspection...................................................156 Installation.................................................156 Rear Shock Absorber..............................................158 Removal......................................................158 Note on Disposal.............................................159 Inspection...................................................159 Adjustment...................................................159 Sving Arm........................................................159 Removal......................................................160 Inspection...................................................161 Drive, Chain, Sprocket and Crown.................................162 Removal......................................................162 Inspection...................................................163 8. Electricals.......................................................164 Index............................................................165 Electrical Circuit Diagram.......................................166 Colour Code..................................................166 Electrical Components............................................167 Switch Check.....................................................168 Switch Connection............................................168 Main Switch Inspection.......................................168 Light Inspection.................................................169 Blub Types...................................................169 Blub Inspection..............................................169 Ignition System..................................................170 Circuit Diagram..............................................170 Diagnostics..................................................171 Electrical Starting System.......................................175 Circuit Diagram..............................................175 Starting Circuit Functioning.................................176 Diagnostics..................................................176 Starter Motor................................................179 Charging System..................................................182 Circuit Diagram..............................................182 Diagnostics..................................................183 Light System.....................................................185 Circuit Diagram..............................................185 Diagnostics..................................................186 Signalling System................................................188 Circuit Diagram..............................................188 Diagnostics..................................................189 Signalling System Control....................................190 Cooling System...................................................195 Circuit Diagram..............................................195 Diagnostics..................................................196 Electrical System Diagram........................................200 9. Troubleshooting...................................................201 Index............................................................202 Failure to Start/Difficulties in Starting........................203 Fuel System..................................................203 Electrical System............................................203 Poor Engine Compression......................................203 Poor Performance at Idle Speed...................................204 Unsatisfactory Performance at Medium-High Speed..................204 Difficulties in Changing Gear....................................204 Gear Change Impossible.......................................204 The Gear Pedal fail to move..................................204 Disengaging Gears............................................204 Clutch Slides or Fails to Release................................205 Clutch Slides................................................205 Clutch Fails to Release......................................205 Overheating of Engine............................................205 Excessive Engine Cooling.........................................205 Defective Brakes.................................................206 Poor Braking.................................................206 Oil Leaks or Malfunctioning of Front Fork........................206 Oil Leaks....................................................206 Malfunctioning...............................................206 Unstable Steering................................................206 Defective Functioning of Lights and Indicators...................207 Poor Headlight Illumination..................................207 Frequent Burning of Blub.....................................207 The Direction Indicators Fail to Turn On.....................207 The Direction Indicators Fail to Turn Off....................207 Delayed Turning on of Indicators.............................207 Excessive Indicator Intermittence Frequency..................207 The Horn Fails to Work.......................................207
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