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Yamaha_SZR660_95_Service Repair Manual
Total 207 Pages
CONTENTS
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION OF MOTORCYCLE
IDENTIFICATION NUMBER ,ENGINE SERIAL NUMBER
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY AND REASSEMBLY,SPARE PARTS,GASKETS, OIL SEALS AND OˇRINGS,LOCK WASHERS PLATES AND COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
SPECIAL TOOLS
CHAPTER 2°
TECHNICAL SPECIFICATIONS,GENERAL SPECIFICATIONS ,MAINTENANCE SPECIFICATIONS ,ENGINE ,ELECTRIC SYSTEM
CHASSIS
TIGHTENING TORQUES ,GENERAL TOROUE SPECIFICATIONS ,DEFINITION OF MEASUREMENT UNITS,LUBRICATION POINTS AND TYPE OF LUBRICANT,ENGINE ,CHASSIS,LUBRICATION LAYOUT ,COOLING LAYOUT ,CABLE ROUTING
CHAPTER 3°
PERIODIC INSPECTION AND ADJUSTMENT
PERIODIC MAINTENANCE/LUBRICATION INTERVALS,SEAT, FUEL TANK AND REAR COWLING,
AEMOVALAND INSTALLATION,COW LING,REMOVAL AND INSTALLATION ,ENGINE ,VALVE ,CLEARANCE ADJUSTMENT ,DRIVE CHAIN ADJUSTMENT,IDLE SPEED ADJUSTMENT,THROTTLE CABLE FREE PLAY ADJUSTMENT,SPARK PLUG INSPECTION,IGNITION TIMING CHECK,COMPRESSION INSPECTION,ENGINE OIL LEVEL CHECK,ENGINE OIL ,REPLACEMENT,ENGINE OIL PRESSURE CHECK,CLUTCH ADJUSTMENT,AIR FILTER CLEANING
SUCTION HOSE AND MANIFOLD INSPECTION,FUEL LINE INSPECTION,CRANKCASE VENTILATION HOSE INSPECTION,EXHAUST SYSTEM INSPECTION,CHECKING THE COOLANT LEVEL,CHANGING THE COOLANT,COOLING SYSTEM INSPECTION
CHASSIS
FRONT BRAKE ADJUSTMENT,REAR BRAKE ADJUSTMENT,BRAKE FLUID LEVEL CHECK,BRAKE PAD WEAR INSPECTION,BRAKE HOSING INSPECTION,,BRAKE CIRCUIT BLEEDING,DRIVE CHAIN TIGHTNESS INSPECTION AND ADJUSTMENT,DRIVE CHAIN LUBRICATION,FRONT FORK INSPECTION AND ADJUSTMENT,SHOCK ABSORBER INSPECTION AND ADJUSTMENT
STEERING INSPECTION ,TYRE INSPECTION ,WHEEL INSPECTION,CABLE INSPECTION AND LUBRICATION,LEVER AND PEDAL LUBRICATION,SIDE STAND LUBRICATION
REAR SWING ARM LUBRICATION,ELECTRICALS ,HEADLIGHT: LAMP REPLACEMENT AND SETTING ,FUSE INSPECTION AND REPLACEMENT ,BATTERY INSPECTION
CHAPTER 4°
ENGINE OVERHAUL
ENGINE REMOVAL,COWLING, SEAT AND FUEL TANK,ENGINE OIL, SYSTEM,SA TTERY CABLES
RADIATOR,EXHAUST PIPE,AIR CLEANER CASE AND CARBURETOR , CLUTCH CABLE,DRIVE CHAIN,ENGINE DETACHMENT
ENGINE DISASSEMBLY,STARTER MOTOR AND HOSES,CYLINDER HEAD CYLINDER AND PISTON,
ROTOR AND STARTER DRIVERS,OIL FILTER AND WATER PUMP,CLUTCH AND BALANCER GEAR ,SHIFT LEVER AND OIL PUMP,CRANKCASE (RIGHT),OIL STRAINER,BALANCER, TRANSMISSION AND SHIFTER,CRANKSHAFT,ROCKER ARM, VALVES,,INSPECTION AND REPAIR,CYLINDER HEAD
VALVES AND VALVE GUIDES,VALVE HOUSING,VALVE SPRING,CAMSHAFT,ROCKER ARMS AND ROCKER ARM SHAFT,CAMSHAFT CHAIN SPROCKET AND CHAIN GUIDE,CAMSHAFT CHAIN ,UIDE
CYLINDER AND PISTON,PISTON RINGS, PISTON PIN,CRANKSHAFT,BALANCER DRIVE GEAR AND BALANCER GEAR,ELECTRIC STARTER DRIVE,PRIMARY DRIVE, CLUTCH,TRANSMISSION AND GEARBOX,OIL PUMP, WATER PUMP AND STRAINER,OIL DELIVERY PIPES,CRANKCASE,
BEARINGS AND OIL SEALS,CIRCLIP AND WASHER,ENGINE ASSEMBLY AND SETTING,VALVES AND AOCKER ARMS,VALVES, ,ROCKER ARMS, CRANKSHAFT,CRANKSHAFT AND BALANCER SHAFT,TRANSMISSION, BALANCER TRANSMISSION AND SHIFTER,OIL STRAINER (EXPLODED VIEW),CRANKCASE (EXPLODED VIEW),SHIFT LEVER AND OIL PUMP,CRANKCASE (ASSEMBLING)
OIL STRAINER (ASSEMBLING), ,SHIFT LEVER AND OIL PUMP,BALANCER SHAFT GEAR
CLUTCH,CLUTCH AND BALANCER GEAR, OIL FILTER AND WATER PUMP,STARTER GEARS,
CYLINDER,CYLINDEA HEAD,CAMSHAFT AND CAMSHAFT CHAIN,CYLINDER HEAD, CYLINDER AND PISTON,PIPES ANO HOSES,ENGINE REASSEMBLY,
CHAPTER 5°
COOLING SYSTEM
COOLING SYSTEM,RADIATOR ,JOB INSTRUCTION CHART,INSPECTIONG,ASSEMBLY, WATER PUMP,JOB INSTRUCTION CHARTH,REMOVAL ,INSPECTION,ASSEMBLY,THERMOSTAT,JOB INSTRUCTION CHART,REMOVAL,INSPECTION,ASSEMBLY
CHAPTER 6°
CARBURETOR
CARBURETOR,TECHNICAL SPECIFICATIONSITIGHTENING TOROUES! EXPLODED VIEWH,SECTION VIEW,REMOVALH-7,DISASSEMBLY,INSPECTION,H-9,ASSEMBLY ,
INSTALLATION,FUEL LEVEL ADJUSTMENT,FUEL PUMP,CHECKING THE PUMP OPERATION ,
REMOVAL ,INSPECTION, INSTALLATION,CHASSIH,
CHAPTER 7°
CHASSIS
FRONT WHEELREMOVAL,INSPECTION ,STATIC BALANCING,REAR WHEEL, ,REMOVAL,INSPECTION,FRONT AND REAR BRAKE ,FRONT MASTER CYLINDER,FRONT BRAKE CALIPER,REAR MASTER CYLINDER,REAR BRAKE CALIPER,BRAKE PAD REPLACEMENT,FRONT BRAKE CALIPER DISASSEMBLY,REAR BRAKE CALIPER DISASSEMBLY,FRONT MASTER CYLINDER DISASSEMBLY ,REAR MASTER CILINDER DISASSEMBLY,INSPECTION AND REPAIR,
FRONTFORK,REMOVAL ,OIL CHANGE,CLEANING THE DUST SEAL,REPLACING THE SEALS AND BUSHES ,ADJUSTMENT ,STEERING,REMOVAL ,INSPECTION,INSTALLATION,REAR SHOCK ABSORBER,REMOVAL,NOTE ON DISPOSAL,INSPECTION ,ADJUSTMENT ,SWING ARMJ,REMOVAL
INSPECTION ,DRIVE CHAIN, SPROCKET AND CROWNK,REMOVAL ,INSPECTION
CHAPTER 8
ELECTRICALS
ELECTRICAL CIRCUIT DIAGRAM ,
COLOUR CODE ,
ELECTRICAL COMPONENTS,
SWITCH CHECK ,
SWITCH CONNECTION ,
MAIN SWITCH INSPECTION ,
LIGHT INSPECTION (HEADLIGHTSTAIL LIGHT AND BRAKE LIGHT,
DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) ,
BULB TYPES ,
BULB INSPECTION,
IGNITION SYSTEM ,
CIRCUIT DIAGRAM ,
DIAGNOSTICS ,
STARTING SYSTEM ,
CIRCUIT DIAGRAM ,
STARTING CIRCUIT FUNCTIONING ,
DIAGNOSTICS ,
STARTER MOTOR ,
CHARGING SYSTEM ,
CIRCUIT DIAGRAM
DIAGNOSTICS
LIGHT SYSTEM
CIRCUIT SYSTEM ,
DIAGNOSTICS‘
SIGNALLING SYSTEMS
CIRCUIT DIAGRAM
DIAGNOSTICS‘ ,
SIGNALLING SYSTEM CONTROL
COOLING SYSTEM ,
CIRCUIT DIAGRAM ,
DIAGNOSTICSM-‘
ELECTRICAL SYSTEM OIAGRAM ,
CHAPTER 9°
TROUBLESHOOTING
FAILURE TO START DIFFICULTIES IN STARTING ,
FUEL SYSTEM Mˇ" ELECTRICAL SYSTEM ,
POOR ENGINE COMPRESSION ,
POOR PERFORMANCE AT IDLE SPEED ,
UNSATISFACTORY PERFORMANCE AT MEDIUMˇHIGH SPEED‘,
DIFFICULTIES IN CHANGING GEAR ,
GEAR CHANGE IMPOSSIBLE ,
THE GEAR PEDAL FAILS TO MOVE ,
DISENGAGING GEARS ,
CLUTCH SLIDES OR FAILS TO RELEASE ,
CLUTCH SLIDES ,
CLUTCH FAILS TO RELEASE ,
OVERHEATING OF ENGINE ,
EXCESSIVE ENGINE COOLING ,
DEFECTIVE BRAKES ,
POOR BRAKING ,
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK ,
OIL LEAKS ,
MALFUNCTIONING,,
UNSTABLE STEERING ,
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS ,
POOR HEADLIGHT ILLUMINATION ,
FREQUENT BURNING OF BULB ,
THE DIRECTION INDICATORS FAIL TO TURN ON ,
THE DIRECTION INDICATORS FAIL TO TURN OFF ,
DELAYED TURNING ON OF INDICATORS ,
EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY .
WARNING
THE MANUAL HAS BEEN WRITTEN BY BELGRADE https://www.tradebit.com MAINLY FO( USE BY YAMAHA DEALERS AND THEIR SKILLED
MECHANICS. IT IS IMPOSSIBLE TO PROVIDE A MECHANIC WITH ALL THE INFORMATION NECESSARY IN A SINGLE MANUAL.
PRESUMABLY . THOUGH, THE PEOPLE WHO USE THIS MANUAL OFF THE MAINTENANCE AND (EPICAL YAMAHA MOTORCADES
WILL ALREADY HAVE ELEMENTARY KNOWLEDGE OF THE PRINCIPLES OF MECHANICS AND THE PROCEDURES FOR MOTOR CYDE
REPAIR TECHNIQUES. W INHAUL THIS KNOWLEDGE, REPAIR OF MAINTENANCE WOO ON THIS MODEL COULD PROVE INEFFICIENT AND/OR DANGEROUS.
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