warning YAMAHA TTR90 2001 Betriebsanleitungen (in German)

INTRODUCTION
Congratulations on your purchase of a
Yamaha TT-R90(N). This model is the culmi-
nation of Yamaha’s vast experience in the pro-
duction of pacesetting racing machines. It
represents the highest grade of craftsmanship
and reliability that have made Yamaha a
leader.
This manual explains operation, inspection,
basic maintenance and tuning of your
machine. If you have any questions about this
manual or your machine, please contact your
Yamaha dealer.
NOTE:

As improvements are made on this model,
some data in this manual may become out-
dated. If you have any questions, please con-
sult your Yamaha dealer.
WARNING

l
READ THIS MANUAL CAREFULLY FOR
INSTRUCTIONS ON HOW TO PROPERLY
OPERATE THIS MACHINE.
l
ADULT INSTRUCTION AND SUPERVI-
SION ARE REQUIRED.
l
WEIGHT OF THE RIDER SHOULD NOT
EXCEED 40 kg (88 lb).
l
ALWAYS WEAR A HELMET AND SUIT-
ABLE PROTECTIVE CLOTHING WHEN
RIDING.
l
DO NOT TOUCH ANY MOVING PARTS OR
HEATED AREAS.
l
ALWAYS PERFORM PRE-OPERATION
CHECKS. REFER TO PAGE 15.
l
THIS MACHINE IS DESIGNED TO CARRY
THE OPERATOR ONLY.
NO PASSENGERS.
l
THIS MACHINE IS DESIGNED OFF-ROAD
USE ONLY.
IT IS NOT SUITABLE FOR ON-ROAD USE.

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of six chapters;
“General Information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis” and “Electrical”.
2. The table of contents is at the beginning
of the manual. Look over the general lay-
out of the book before finding then
required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.
WARNING
CAUTION:

1 - 9
GEN
INFO

CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
“ENGINE STOP” SWITCH
Make sure that the engine stop switch
1
is
positioned to “ ”. The engine stop switch has
been equipped to ensure safety in an emer-
gency such when the machine is up set or
trouble takes place in the throttle system. The
engine will not start or run when the engine
stop switch is turned to “ ”.
SHIFT PEDAL
The gear ratios of the constant-mesh 3 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal
1
on
the left side of the engine.
WARNING

When starting out on the machine, shift the
transmission into 1st after pulling in the
front brake lever and closing the throttle
grip.
KICK STARTER
WARNING

Before starting the engine, be sure to shift
the transmission into neutral.
Rotate the kick starter
1
away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine.
EC155001
THROTTLE GRIP
The throttle grip
1
is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.

1 - 11
GEN
INFO

CONTROL FUNCTIONS/FUEL
FUEL TANK CAP
Remove the fuel tank cap
1 by turning
counter-clockwise.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine.
FUEL
Use regular gasoline. Always use fresh, name
brand gasoline.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine. Do not fill the fuel
tank above the bottom of the filler tube 1
as shown in the illustration or it may over-
flow when the fuel heats up later and
expands.
aFuel level
Recommended fuel:
For USA:
Unleaded fuel
For CDN and EUROPE:
Rgular unleaded gasoline
For AUS:
Unleaded fuel only
For NZ:
Regular gasoline
Fuel tank capacity:
Total:
4.2 L (0.92 lmp gal, 1.11 US gal)
Reserve:
0.5 L (0.11 lmp gal, 0.13 US gal)

GEN
INFO
1 - 12
STARTING AND OPERATION
STARTING AND OPERATION
CAUTION:
Prior to operating the machine, perform
steps listed in pre-operation check list.
WARNING
Never start your engine or let it run for any
length of time in a closed area. The exhaust
fumes are poisonous and can cause loss of
consciousness and death within a short
time. Always operate your machine in an
area with adequate ventilation.
STARTING A COLD ENGINE
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
1. Turn the fuel cock to “ON”.
2. Operate the starter (choke) and com-
pletely close the throttle grip.
3. Slide the “ENGINE STOP” switch to the
“”.
4. Kick the kick starter with full strength to
start the engine.
5. After the engine starts, warm up for one
or two minutes. Make sure the stater
(choke) is returned to the original position
before riding.
STARTING A WARM ENGINE
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke)
should not be used. The throttle should be
opened slightly.
CAUTION:
See “Engine break-in Section” prior to
operating engine for the first time.WARMING UP
To get maximum engine life, always “warm-up”
the engine before starting off. Never acceler-
ate hard with a cold engine! To see whether or
not the engine is warm, see if it responds to
throttle normally with the stater (choke) turned
off.
WARNING
Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.
ENGINE BREAK-IN
Brake-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially
of slack cables and drive chain and loose
spokes.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.

3 - 3
INSP
ADJ

ENGINE/THROTTLE CABLE ADJUSTMENT/
AIR FILTER CLEANING
EC350000
ENGINE
THROTTLE CABLE ADJUSTMENT
1. Check:
l
Throttle grip free play
a

Out of specification
®
Adjust.
Throttle grip free play
a
:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
l
Throttle grip free play
AIR FILTER CLEANING
NOTE:

Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:

Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.Throttle grip free play adjustment steps:
Turning in: Free play is increased.
Turning out: Free play is decreased.
l
Tighten the locknut.
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
lLoosen the locknut 1 on throttle cable.
lTurn the adjuster 2 in or out until the
specified free play is obtained.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.

3 - 10
INSP
ADJ
SPARK ARRESTER CLEANING (For USA)
6. Install:
lTappet cover (intake side) 1
lO-ring 2
7. Install:
lTappet cover (exhaust side)
lO-ring
lSpark plug
lTiming plug
lCrankshaft end cover
8. Install:
lAir filter case
lAir scoop (right)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
New
T R..18 Nm (1.8 m · kg, 13 ft · lb)
New
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
SPARK ARRESTER CLEANING (For USA)
WARNING
lBe sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
lDo not start the engine when cleaning the
exhaust system.
1. Remove:
lBolt (tailpipe) 1
2. Remove:
lTailpipe 2
Pull the tailpipe out of the muffler.
3. Clean:
lSpark arrester
Use a wire brush to remove any carbon
deposits from the spark arrester portion
of the tailpipe.
Tap the tailpipe lightly and remove the
carbon deposits from the outside por-
tion of the tailpipe.
4. Install:
lTailpipe
Insert the tailpipe into the muffler and
align the bolt hole.
lBolt (tailpipe)
2
1
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

3 - 16
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
3. Check:
lSteering smooth action
Turn the handlebar lock to lock.
Unsmooth action ® Adjust steering ring
nut.
4. Adjust:
lSteering ring nut
Steering ring nut adjustment steps:
lRemove the front fender 1.
lRemove the handlebar and handle crown.
lLoosen the ring nut 2 using the ring nut
wrench 3.
Ring nut wrench:
YU-1268/90890-01268
lTighten the ring nut 4 using ring nut
wrench 5 and turn the steering right and
left a few times.
Ring nut wrench:
YM-33975/90890-01403
T R..
Ring nut (initial tightening):
38 Nm (3.8 m • kg, 27 ft • lb)
lLoosen the ring nut one turn.
lRetighten the ring nut using the ring nut
wrench.
T R..
Ring nut (final tightening):
1 Nm (0.1 m • kg, 0.7 ft • lb)
lCheck the steering shaft by turning it lock
to lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
lInstall the handle crown 6, handlebar 7,
and front fender.
2 3
5
4
NOTE:
Set the torque wrench to the ring nut
wrench so that they form a right angle.
WARNING
Avoid over-tightening.

4 - 6
ENGCARBURETOR
EC464600
Float
1.Inspect:
lFloat 1
Damage ® Replace.
ASSEMBLY AND INSTALLATION
Carburetor
1.Install:
lPilot air screw 1
Note the following installation points:
lScrew in the pilot air screw until it is lightly
seated.
lBack out it by the specified number of
turns.
Pilot air screw:
1-3/4 turns out
2.Install:
lThrottle valve 1
lStarter plunger 2
NOTE:
Align the slit a of the throttle valve with the tab
b of the carburetor top.
FUEL LEVEL ADJUSTMENT
WARNING
Gasoline (fuel) and its vapors are highly
flammable and explosive. Keep away from
sparks, cigarettes, flames or other sources
of ignition.

5 - 1
CHAS

EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL AND FRONT BRAKE
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

FRONT WHEEL AND REAR WHEEL
5