check engine light YAMAHA TTR90 2002 Owners Manual

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GEN
INFO
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.

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INSP
ADJ
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for several
minutes and wait for five minutes.
2. Place the machine on a level place and
hold it up on upright position by placing
the suitable stand under the engine.
3. Remove:
lDipstick 1
4. Check:
lOil level
Oil level should be between maximum
a and minimum b marks.
Oil level is low ® Add oil to proper
level.
NOTE:
When inspecting the oil level, do not screw the
dipstick into the oil tank. Insert the gauge
lightly.
(For USA and CDN)
CAUTION:
lDo not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
lDo not allow foreign material to enter the
crankcase.
Recommended oil:
At –10 ˚C (10 ˚F) or higher :
Yamalube 4 (10W-30) or SAE
10W-30 type SE/SF motor oil
At 5 ˚C (40 ˚F) or higher õ:
Yamalube 4 (20W-40) or SAE
20W-40 type SE/SF motor oil010 30 50 70
90110
130
-20
-10010
20 30 40
50

õ
˚C˚F
ENGINE OIL LEVEL INSPECTION

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INSP
ADJ
ELECTRICAL/SPARK PLUG INSPECTION
EC370000
ELECTRICAL
EC371001
SPARK PLUG INSPECTION
1. Remove:
lSpark plug
2. Inspect:
lElectrode 1
Wear/damage ® Replace.
lInsulator color 2
Normal condition is a medium to light
tan color.
Distinctly different color ® Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure:
lPlug gap a
Use a wire gauge or thickness gauge.
Out of specification ® Regap.
4. Clean the plug with a spark plug cleaner
if necessary.
Spark plug gap:
0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Standard spark plug:
CR6HSA (NGK)
U20FSR-U (DENSO)
5. Tighten:
lSpark plug
NOTE:
lBefore installing a spark plug, clean the gas-
ket surface and plug surface.
lFinger-tighten a the spark plug before
torquing to specification b.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)

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ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION
EC4H3000
REMOVAL POINTS
Shift fork, shift cam and transmission
1. Remove:
lShift forks
lShift cam
lDrive axle assembly
lMain axle assembly
NOTE:
lTap lightly on the transmission drive axle and
shift cam with a soft hammer to remove.
lRemove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
ASSEMBLY AND INSTALLATION
Transmission, shift cam shift fork
1. Install:
lMain axle assembly 1
lDrive axle assembly 2
2. Install:
lShift fork 1 “L” 1
lShift fork 2 “R” 2
lShift cam 3
lGuide bar 4
NOTE:
The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “L”.
3. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.