oil YAMAHA TTR90 2000 Service Manual

4 - 38
ENGOIL PUMP
INSPECTION
Oil pump
1. Measure:
lTip clearance a
(between the inner rotor 1 and the
outer rotor 2)
lSide clearance b
(between the outer rotor 2 and the
rotor housing 3)
Out of specification ® Replace the oil
pump assembly.
lRotor housing and rotor clearance c
(between the rotor housing 3 and the
rotors 1 2)
Out of specification ® Replace the oil
pump assembly.
Tip clearance a:
0.15 mm (0.0059 in)
: 0.2 mm (0.0079 in)
Side clearance b:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
: 0.15 mm (0.006 in)
Rotor housing and rotor clear-
ance c:
0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)
: 0.23 mm (0.0091 in)
Rotary filter and oil strainer
1. Inspect:
lRotary filter 1
lOil strainer 2
Damage ® Replace.
3Upper side
4Lower side
INSTALLATION
Rotary filter
1. Install:
lRotary filter 1
NOTE:
When installing the rotary filter, align the match
mark a on the rotary filter with the hole b of
the crankshaft.

4 - 39
ENG

CDI MAGNETO
CDI MAGNETO
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
LT
3
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
T R..48 Nm (4.8 m •
kg, 35 ft • Ib)
45
2
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)2
1

Extent of removal:
1
Pickup coil/stator assembly removal
2
Rotor removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO AND STATOR
REMOVAL
Preparation for removal Fuel tank
Crankcase cover (left) Refer to “CLUTCH” section.
1 CDI magneto coupler 1
2 Pickup coil/stator assembly 1
3 Rotor nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 4 Rotor 1
5 Woodruff key 1
1
2

4 - 41
ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
Extent of removal Order Part name Q’ty Remarks
CRANKCASE SEPARATION
AND CRANKSHAFT REMOVAL
Preparation for removal Seat and fuel tank
Exhaust pipe
Air filter case
Carburetor Refer to “CARBURETOR” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Engine guard
Engine assembly From the chassis.
Cylinder head Refer to “CYLINDER HEAD” section.
Cylinder and piston Refer to “CYLINDER AND PISTON” sec-
tion.
Clutch housing and clutch carrier Refer to “CLUTCH” section.
Kick axle assembly Refer to “KICK AXLE” section.

4 - 42
ENGCRANKCASE AND CRANKSHAFT
Extent of removal:1 Timing chain removal2 Drive sprocket removal
3 Crankcase separation4 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
Shift shaft Refer to “SHIFT SHAFT” section.
Oil pump and oil strainer Refer to “OIL PUMP” section.
Rotor Refer to “CDI MAGNETO” section.
1 Timing chain guide (intake) 1
2 Timing chain 1
3 Drive sprocket 1
4 Crankcase (right) 1
5 Dowel pin 2
6 Crankshaft 1
7Crankcase (left)
1
1
23
4

4 - 43
ENG

CRANKCASE AND CRANKSHAFT
INSPECTION
EC4N4201
Crankshaft
1. Measure:
l
Runout limit
a

l
Connecting rod big end side clearance
b

l
Connecting rod big end radial clear-
ance
c

l
Crank width
d

Out of specification
®
Replace.
Use the dial gauge and a thickness
gauge.
Standard Limit
Runout
limit—0.03 mm
(0.0012 in)
Side
clearance0.1 ~ 0.4 mm
(0.0039 ~ 0.0157 in)—
Radial
clearance0.010 ~ 0.025 mm
(0.0004 ~ 0.0010 in)0.05 mm
(0.002 in)
Crack
width42.95 ~ 43.00 mm
(1.691 ~ 1.693 in)—
Crankcase
1. Apply:
l
Sealant
On the crankcase (left).
NOTE:

l
Clean the contacting surface of crankcase
(left and right) before applying the sealant.
l
DO NOT ALLOW any sealant to come in
contact with the oil gallery
a
.
Quick gasket
®

:
ACC-QUICK-GS-KT
Yamaha bond No. 1215:
90890-85505

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

CHAS

5 - 5
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
AUSBAU
Radlager (nach Bedarf)
1. Demontieren:
l
Lager
1

HINWEIS:

Die Lager mit einem Lageraustreiber
2
aus-
bauen.
PRÜFUNG
Rad
1. Messen:
l
Felgenschlag
Unvorschriftsmäßig
®
Instand setzen/
Erneuern.
Max. Felgenschlag
Höhenschlag
1
2,0 mm
Seitenschlag
2
2,0 mm
Bremsbeläge
1. Kontrollieren:

l
Trommelbremsbelag
Glasige Oberfläche
®
Anschleifen.
grobes Sandpapier verwenden.
HINWEIS:

Nach dem Anschleifen die Schleifpartikel mit
einem Lappen abwischen.
2. Messen:
l
Trommelbremsbelag-Stärke
Unvorschriftsmäßig
®
Erneuern.
Meßpunkte
HINWEIS:

Trommelbremsbeläge immer komplett erneu-
ern, auch wenn nur ein Belag die Verschleiß-
grenze erreicht hat.
Trommelbremsbelag-Stärke
a

Standard
3 mm
Grenzwert
2 mm
POINTS DE DEPOSE
Roulement de roue (si nécessaire)
1. Déposer:
l
Roulement
1
N.B.:

Déposer le roulement en utilisant un arrache-roule-
ment courant
2
.
CONTROLE
Roue
1. Mesure:
l
Voile de roue
Hors limite
®
Réparer/changer.
Limite de voile de la roue:
Radial 1: 2,0 mm (0,08 in)
Latéral 2: 2,0 mm (0,08 in)
Garnitures de frein
1. Examiner:
lSurface de garniture de mâchoire de frein
Zones brillantes ® Poncer.
Utiliser du papier de verre à gros grains.
N.B.:
Après ce ponçage, éliminer les particules avec un
chiffon.
2. Mesurer:
lEpaisseur de garniture de mâchoire de frein
Hors spécifications ® Remplacer.
Endroits à mesurer
N.B.:
Remplacer les deux mâchoires de frein si l’une
d’elles est usée à la limite.
Epaisseur de garniture de mâchoire
de frein a:
Standard:
3 mm (0,12 in)
Limite:
2 mm (0,08 in)

5 - 7
CHAS

FRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:
1
Oil seal removal
2
Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
Preparation for disas-
semblyDrain the fork oil.
1
Adjuster 1
2
Fork spring 1
3
Dust cover 1
4
Stopper ring 1
5
Bolt (damper rod) 1
Use special tool.
Refer to “REMOVAL POINTS”.
6
Inner tube 1
7
Damper rod 1
8
Oil seal 1
9
Outer tube 1
12

5 - 8
CHASFRONT FORK
REMOVAL POINTS
Inner tube
1. Remove:
lBolt (damper rod)
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2, loosen the bolt
(damper rod).
Damper rod holder:
YM-01300/90890-01294
T-handle:
YM-01326/90890-01326
EC555000
ASSEMBLY AND INSTALLATION
1. Install:
lOil seal 1
NOTE:
Press the oil seal into the outer tube with fork
seal driver weight 2 and fork seal driver
attachment 3.
2. Fill:
lFork oil
Fork seal driver weight:
YM-33963/YM-01442/90890-01184
Fork seal driver attachment:
YM-1369/90890-01186
Oil quantity:
64 cm3 (2.26 Imp oz, 2.16 US oz)
Recommended oil:
Fork oil 15W or equivalent
3. After filling up, slowly pump the fork up
and down to distribute the fork oil.

6 - 1
–+ELEC

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
CDI magneto
2
CDI unit
3
Ignition coil
4
Spark plug
5
“ENGINE STOP” switch
6
Thermo switch
7
Carburetor heater
8
Rectifier/regulator
COLOR CODE
B...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
W..................... White
EC612000
WIRING DIAGRAM
G/WB/RW/LW/RBr G
RW
WB
Y/R
O
BO
B
B
BY/RY
WY/RB
W
Y
B
GG/W
B/W
B/W
BrB/RWWWY
OO
BBW/LY/RR
W
B
B
B
W/R
Y/R
OFF
RUN
B
Y/R
B
B
Y
Y
1
23
4
5 6
7 8

B/R ................... Black/Red
B/W .................. Black/White
G/W.................. Green/White
W/L .................. White/Blue
W/R .................. White/Red
6