Yamaha SZR 660 Manuel utilisateur

YAMAHA

4SU-ME1

SERVICE

SZR660('95)

SERVICE MANUAL

R&D TECHNICAL DIVISION

V* edition February 1996

Any reprinting or unauthorised use

without the written permission ol

Belgarda S.p.A, is

expressly prohibited.

Although some of the drawings andphotographs used in this manual are taken from other manuals and do not refer directly to the mode?

in question, meprocedures described and the details illustrated are nonetheless relevant and suitable to the user's purposes.

WARNING HOW TO USE THIS MANUAL

This manual has been written by Belgarda S.pA mainiy for use by Yamaha dealers and their skilled

mechanics. It is impossible to provide amechanic with all the information necessary in asingle manual.

Presumably, though, the people who use this manual for the maintenance and repair of Yamaha motorcycles

will already have elementary knowledge of the principles of mechanics and the procedures for motorcycle

repair techniques. Without this knowledge, repair or maintenance work on this model could prove inefficient

and/or dangerous.

Yamaha makes constant efforts to improve all its models. Important alterations or changes to procedures

characteristics will be communicated to all Yamaha dealers and published in future editions of this manual.

Especially important information in this manual is highlighted by the graphics shown below.

TECHNICAL PUBLICATIONS

R&D TECHNICAL DIVISION

MOTORCYCLE GROUP

BELGARDA S.p.A.

PARTICULARLY IMPORTANT INFORMATION

The manual includes the following symbols and relative remarks:

AWARNING

CAUTION:

NOTE:

This safety alert symbol means: ATTENTION" BE CAREFUL! YOUR SAFETY IS

AT RISK!

The WARNING symbol indicates special procedures to be followed to avoid injury

to the rider or the person inspecting or repairing the cycle.

CAUTION indicates special precautions to be taken to avoid damage to the cycle.

ANOTE provides key information designed to make procedures easier or clearer.

LAYOUT

This manual consists of chapters on the principal cycle components (see "Symbol Legend").

(1)

(2)

(3)

This symbol, in the top right-hand corner of each page, identifies the chapter graphically.

This title appears at the top of each page to the left of the chapter symbol,

The final caption in the chapter "Periodic inspection and adjustment".

FORMAT

All the procedures suggested in this manual are arranged in asequential, step by step order. The information

is written in such away as to provide the mechanic with ahandy, 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 (*) 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).

•Anumber inscribed in round brackets indicates (6) the number of apart, whereas aletter of the alphabet

indicates alignment data or marks (7); further indications are signalled by aletter eclosed in an inset (8).

•The condition of afaulty component precedes Qn 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

atable 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.

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SYMBOL LEGEND

(Refer to illustrations)

Symbols (1) to (9) are used to indicate chapter

number and content.

)

General information

(2) Technical specifications

(3) Periodic inspection and adjustment

(4) Engine overhaul

(5) Cooling system

(6) Carburetor

(7) Chassis

(8) Electricals

(9) Troubleshooting

Symbols (10) to (16) serve to specify the following

elements:

(10) Fluid

(11) Lubricant

(12) Special tool

(13) Screw tightening

(14) Wear and tear limit, clearance

(15) Engine speed

(16) Resistance (fi), Voltage (V), Electric Current (A)

Symbols (17) to (23) in the exploded diagram

indicate type of lubricant and location of lubrication

point

(17) Appfy engine oil

(18) Apply gear oil

(19) Apply molybdenum disulfide oil

(20) Apply wheel bearing grease

(21) Apply lightweight lithium-soap grease

(22) Apply molybdenum disulfide grease

(23) Apply locking liquid (LOCTJTE®)

CONTENTS

GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

PERIODIC INSPECTION

AND ADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETOR

CHASSIS

GEN

INFO

INSP

ADJ H

ENG

5OOLH

EARB

<&%)

CHAS

CHAPTER 1°

GENERAL INFORMATION

GEN

INFO

IGEN

INFO #^

IDENTIFICATION OF MOTORCYCLE A-6

IDENTIFICATION NUMBER A-6

ENGINE SERIAL NUMBER A-6

IMPORTANT INFORMATION A-6

PREPARATION FOR DISASSEMBLY AND REASSEMBLY A-6

SPARE PARTS A-7

GASKETS, OIL SEALS AND O-RINGS A-7

LOCK WASHERS, PLATES AND COTTER PINS A-7

BEARINGS AND OIL SEALS A-7

CIRCUPS A-7

SPECIAL TOOLS A-7

IDENTIFICATION OF MOTORCYCLE GEN

INFO <^N§

1. Motorcycle identification number

1. Engine serial number

IDENTIFICATION OF MOTORCYCLE

IDENTIFICATION NUMBER

The identification number is stamped on the right of

the steering head pipe.

Progressive serial number:

SZR 660

4SU-040101 (D) version

ZD04SU10000000101 (l-GR-P) version

ZD04SU1 00000201 01

[F-B-N-S-DK-NL-(A-CH)] version

ZD04SU10000060101 (E) version

ENGINE SERIAL NUMBER

The engine seriaf number is stamped on the right of

the engine-

Progressive engine serial number:

SZR 660

4SU-000101

NOTE:

The first three digits in these numbers identify the

model; the other digits form the progressive

production number of the unit.

Diagrams and specifications may be altered

without prior warning.

IMPORTANT INFORMATION GEN

INFO &%

IMPORTANT INFORMATION

PREPARATION FOR DISASSEMBLY AND

REASSEMBLY

1.Remove all dirt, mud, dust and foreign objects

prior to disassembly.

2. Use proper material and toots. Refer to sec-

tion 'SPECIAL TOOLS',

3. When disassembling the cycle, keep together

mated parts: gears, cylinders, pistons and

other parts 'mated' in the course of normal

wear and tear. Such parts must be either re-

used together or completely replaced.

4. During disassembly, clean all parts and place

them in trays in order of disassembfy. This

makes reassembly quicker and helps assure

that all parts are assembled properly.

5. Keep away from fire and sources of heat.

1-1 1-2

IMPORTANT INFORMATION GEN

INFO <^N§

SPARE PARTS

1. We recommend original Yamaha parts for all

replacements. Use the oil and grease recom-

mended by Yamaha for all assembly and

adjustment operations.

Products of other makes with the same func-

tion and appearance might be inferior in

quality.

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals and O-rings should be

replaced during engine overhauls. All gasket

surfaces, oil seal lips and O-rings must be

cleaned prior to assembly.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to oil seal

lips.

LOCK WASHERS, PLATES AND COTTER PINS

1.All lock washers, plates (1 )and cotter pins

must be replaced once removed. Lock tabs

must be bent along the bolt or nut surfaces

after the bolt or nut has been properly tight-

ened.

BEARINGS AND OIL SEALS

1.Fit bearings and oil seals with the manufactur-

er's mark or number facing outwards (ie, the

stamped letters must be visible). When install-

ing oil seals, apply alight coating of lightweight

lithium-based grease to the seal lips. Oil the

bearings liberally when installing.

(1) Oil seals

(£>

1f//J

CAUTION:

Do not use compressed air to dry the bearings.

This damages their outer surface.

(1) Bearing

IMPORTANT INFORMATION/

SPECIAL TOOLS GEN

INFO g!N*5

CIRCLIPS

1.All cirdips should be inspected carefully prior

to reassembly. Always replace piston ring

clips after one use.

Replace twisted cirdips. When installing a

circlip (1), make sure that the sharp-edged

corner (2) is positioned opposite the thrust (3)

it receives. See the illustration here.

(4) Shaft

SPECIAL TOOLS

Special tools are required to perform proper disas-

sembly and reassembly operations and for proper

tuning up. The use of such tools avoids damage

due to the use of unsuitable tools and/or makeshift

techniques.

The shape and part number used for the speciaf

tool differ by country, so two types are provided.

Refer to the list provided to avoid errors when

placing an order.

For USA, CDN

p/N. YM-nnnnn,

YS-QDDQD,

ACC-nODDD

Except for USA, CDN

P/N. 90890-aunon

YU-DDDDa

YK-OUDDD

Tool number Tool name Illustration

YM-08035 VALVE ADJUSTMENT TOOL

90890-01311 VALVE ADJUSTMENT TOOL

Cj* ji'

YU-08036-A INDUCTIVE ENGINE

SPEED INDICATOR M

1-3 1-4

SPECIAL TOOLS GEN

INFO #^

Tool number Tool name

90890-03113

YM-33277-A

90890-03141

YU-33223

90890-03081

YU-33223-3

90890-04082

YM-01312-A

90890-01312

YU-01304

INDUCTIVE ENGINE

SPEED INDICATOR

INDUCTIVE STROBOSCOPE LAMP

INDUCTIVE STROBOSCOPIC LAMP

PRESSURE GAUGE

ADAPTER FOR PRESSURE GAUGE

FUEL LEVEL GAUGE

Illustration

FUEL LEVEL GAUGE

PISTON PIN CLIP PULLER

^\\ '

SPECIAL TOOLS GEN

INFO <?JN5

Tool number

90890-01304

YS-01880

90890-01 701

YU-33270

90890-01362

YM-04063-A

90890-04063

YM-91042

90890-04086

YU-01135-A

Tool name

PISTON PIN CUP PULLER

ROTOR HOLDER

ROTOR SCREW PULLER

ADAPTER FOR ROTOR SCREW

PULLER

ADAPTER FOR ROTOR SCREW

PULLER

ALL-PURPOSE CLUTCH HOLDER

CRANKCASE SEPARATING TOOL

Illustration

.-^

©a

f^a

1-5 1-6

SPECIAL TOOLS GEN

INFO #^

Tool number

90890-01135

YU-01083-A

90890-01083

90890-01084

YM-04019

90890-04019

YM-91043

YM-04064

90890-04064

YM-04066

Tool name

CRANKCASE SEPARATING TOOL

SLIDING HAMMER UNIT

SLIDING HAMMER BOLT

Illustration

SLIDING HAMMER WEIGHT

VALVE SPRING COMPRESSION

CLAMP

VALVE SPRING COMPRESSION

CLAMP

VALVE HOUSJNG CUTTER

6mm (0.24 in) VALVE GUIDE PULLER

6mm (0.24 in) VALVE GUIDE REAMER

IV ri

jOn?

SPECIAL TOOLS GEN

INFO $^5

Tool number

90890-04066

YM-04065-A

90890-04065

YU-90050

90890-01274

90890-01275

YM-90069

90890-04059

YM-91044

90890-04081

Tool name

6mm (0-24 in) VALVE GUIDE REAMER

6mm (0.24 in) VALVE GUfDE

INSTALLER

6mm (0.24 in) VALVE GUIDE

INSTALLER

DRIVING SHAFT

INSTALLATION UNIT

DRIVING SHAFT

INSTALLATION HOSE

DRIVING SHAFT

INSTALLATION BOLT

#10 (M14) ADAPTER

(FOR DRIVING

SHAFT INSTALLATION)

#10 (M14) ADAPTER

(FOR DRIVING

SHAFT INSTALLATION)

CRANK SPACER

Illustration

1-7 1-8

SPECIAL TOOLS

Tool number

90890-01288

Tool name

SPACER (FOR CRANK)

ACC-11001-01

90890-85505

YU-24460-01

90890-01325

YU-33984

SEALANT (QUICK GASKET)'

Yamaha Bond No. 1216®

SEALANT (QUICK GASKET)®

Yamaha Bond No- 1215®

Illustration

RADIATOR CAP TESTER

ADAPTER

(FOR RADIATOR CAP TESTER)

90890-01352 ADAPTER

(FOR RADIATOR CAP TESTER)

4SU-F8120-W0

YU-01268

90890-01268

FRONT FORK SERVICE KIT ASSY

RING NUT WRENCH

Tool number

90890-01385

YM-34487

90890-03144

YU-031 1

90890-03112

Tool name

RING NUT WRENCH

D1NAM1C SPARK TESTER

IGNITION CHECKER

POCKET TESTER

SPECIAL TOOLS GEN

INFO <^^5

Illustration

1-9 1-10

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