brake YAMAHA TTR90 2000 User Guide

3 - 11
INSP
ADJCHASSIS/FRONT BRAKE ADJUSTMENT/
REAR BRAKE ADJUSTMENT
T304002
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
lBrake lever free play a
Out of specification ® Adjust.
Free play (brake lever):
10 ~ 20 mm (0.39 ~ 0.79 in)
(at brake lever end)
a
2
1
2. Adjust:
lBrake lever free play
REAR BRAKE ADJUSTMENT
1. Check:
lBrake pedal free play a
Out of specification ® Adjust.
2. Adjust:
lBrake pedal free play Adjustment steps:
lLoosen the locknut 1.
lTurn the adjusters 2 in or out until the
specified free play is obtained.
Turning in: Free play is increased.
Turning out: Free play is decreased.
Free play:
10 ~ 20 mm (0.39 ~ 0.79 in)
Adjustment steps:
lTurn the adjuster 1 in or out until the
specified free play is obtained.
Turning in: Free play is decreased.
Turning out: Free play is increased.
CAUTION:
Make sure that there is no brake drag
after adjusting the front brake lever free
play.
a
1
CAUTION:
Make sure that the brake does not drag
after adjusting it.

3 - 13
INSP
ADJFRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT
lTighten the wheel axle nut while pushing
down the drive chain.
T R..
Axle nut:
60 Nm (6.0 m • kg, 43 ft • lb)
EC36C000
FRONT FORK INSPECTION
1. Inspect:
lFront fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage ® Repair
or replace.
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
lSwingarm smooth action
Abnormal noise/unsmooth action ®
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage ® Replace.
EC36M012
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the
suitable stand under the engine.
2. Remove:
lRear shock absorber
Refer to “SWINGARM” section in the
CHAPTER 5.
3. Remove:
lSpring guide 1
NOTE:
While compressing the spring, remove the
spring guide.

3 - 18
INSP
ADJ
LUBRICATION
EC36a041
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Brake lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Brake cable endUse Yamaha cable lube or equivalent on these
areas.
õUse SAE 10W30 motor oil or suitable chain
lubricants.
‚Lubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC
78

5 - 1
CHAS

EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL AND FRONT BRAKE
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Bolt (brake cable holder) 1 Only loosening.
2 Brake cable 1 Disconnect at the lever side.
3 Wheel axle nut 1
4 Front wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9Bearing
2Refer to “REMOVAL POINTS”.
WARNING
Support the machine securely so there is nodanger of it falling over.
2
31
3

5

5 - 2
CHAS

Extent of removal Order Part name Q’ty Remarks
10 Brake shoe 2
11 Brake camshaft lever 1
12 Brake camshaft 1
3

FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS

FRONT WHEEL AND REAR WHEEL
EC598100
REAR WHEEL AND REAR BRAKE
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Brake rod 1
2 Cotter pin 1
3 Nut (tension bar) 1
4 Bolt (tension bar) 1
5 Wheel axle nut 1
6 Rear wheel axle 1
7 Drive chain puller 2
8 Rear wheel 1
9 Collar (right) 1
10 Brake shoe plate assembly 1
WARNING
Support the machine securely so there is nodanger of it falling over.
231

5 - 4
CHAS

FRONT WHEEL AND REAR WHEEL
Extent of removal Order Part name Q’ty Remarks
11 Collar (left) 1
12 Wheel drive hub assembly 1
13 Bearing 2 Refer to “REMOVAL POINTS”.
14 Brake shoe 2
15 Brake camshaft lever 1
16 Brake camshaft 1
3
2

5 - 5
CHAS

FRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:
l
Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
1 1
2
1

EC594000
INSPECTION
EC514100
Wheel
1. Measure:
l
Wheel runout
Out of limit
®
Repair/replace.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)
Brake lining
1. Inspect:
l
Brake shoe lining surface
Glazed areas
®
Polish.
Use coarse sand paper.
NOTE:

After polishing, wipe the polished particles with
a cloth.
2. Measure:
l
Brake shoe lining thickness
Out of specification
®
Replace.
Measuring points
NOTE:

Replace the brake shoes as a set if either is
worn to the limit.
Brake shoe lining thickness
a
:
Standard:
3 mm (0.12 in)
Limit:
2 mm (0.08 in)

5 - 6
CHAS

FRONT FORK
EC550000
FRONT FORK
Extent of removal:
1
Front fork removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND FRONT
BRAKE” section.
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Brake cable holder 1
2 Cap bolt 1
3 Adjuster 1 Only loosening.
4 Pinch bolt (under bracket) 1 Only loosening.
5 Front fork 1
WARNING
Support the machine securely so there is nodanger of it falling over.
1

5 - 9
CHASHANDLEBAR
EC5B000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
HANDLEBAR REMOVAL
1 “ENGINE STOP” switch 1
2 Brake lever cable 1 Disconnect at the lever side.
3 Brake lever 1
4 Grip cap (lower) 1
5 Grip cap (upper) 1
6 Throttle cable 1 Disconnect at the throttle side.
7 Grip (right) 1
8 Tube guide 1
9 Grip (left) 1
10 Handlebar holder (upper) 2
11 Handlebar 1
12 Handlebar holder (lower) 2
1