engine YAMAHA TTR90 2003 User Guide

GEN
INFO

DESCRIPTION
FAHRZEUGBESCHREIBUNG
ALLGEMEINE ANGABEN
FAHRZEUGBESCHREIBUNG
1
Motorstoppschalter “ENGINE STOP”
2
Hauptschalter
3
Startschalter
4
Handbremshebel
5
Gasdrehgriff
6
Motoröl-Einfüllschraubverschluß/Tauchstab
7
Kickstarter
8
Kraftstofftank
9
Luftfilter
0
Fußbremshebel
A
Kraftstoffhahn
B
Chokehebel
C
Antriebskette
D
Schalthebel
E
Teleskopgabel
HINWEIS:


Leichte Modell-Abweichungen möglich.

Änderungen an Design und technischen Da-
ten jederzeit vorbehalten.
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1
Coupe-circuit du moteur
2
Commutateur principal
3
Commutateur de démarrage
4
Levier de frein avant
5
Poignée d’accélérateur
6
Bouchon d’orifice de remplissage et jauge d’huile
7
Kick
8
Réservoir de carburant
9
Filtre à air
0
Pédale de frein arrière
A
Robinet à essence
B
Levier de starter
C
Chaîne de transmission
D
Pédale de sélection
E
Fourche avant
N.B.:


Votre machine diffère peut-être partiellement de
celles montrées sur ces photos.

La conception et les caractéristiques peuvent
êtres changées sans préavis.
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1

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GEN
INFO

MACHINE IDENTIFICATION
EC120001
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the
number to your Yamaha dealer for posi-
tive identification of the model you own.
2. If your machine is stolen, the authorities
will need the number to search for and
identify your machine.
KEY IDENTIFICATION NUMBER
The key identification number
1
is stamped
on the key as shown in the following illustra-
tion. This number can be used for ordering a
new key.
EC121001
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number
1
is
stamped on the right of the steering head pipe.
1

ENGINE SERIAL NUMBER
The engine serial number
1
is stamped into
the elevated part of the left-side of the engine.
EC124000
MODEL LABEL
The model label
1
is affixed to the frame
under the rider’s seat. This information will be
needed to order spare parts.
1

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GEN
INFO

IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates
1
and cotter pins
must be replaced when they are
removed. Lock tab(s) should be bent
along the bolt or nut flat(s) after the bolt
or nut has been properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s)
1
and oil seal(s)
2
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:

Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.

1 - 6
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-” or “ACC-”.
For others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1083-A
90890-01084
90890-01085Slide hammer set
Weight
Slide hammer bolt
These tools are used when removing or installing the
rocker arm shafts.YU-1083-A 90890-01084
90890-01085
YU-1268, 90890-01268 Ring nut wrench
This tool is used when loosen the steering ring nut to
specification.YU-1268 90890-01268
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YU-8036-B
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-B 90890-03113
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-1300
90890-01294Damper rod holder set
Damper rod holder
Use this tool to remove and install the damper rod.YM-1300 90890-01294
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.YU-1304 90890-01304

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GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
MAIN SWITCH
Functions of the respective switch positions
are as follows:
ON: The engine can be started only at this
position.
OFF: All electrical circuits are switched off.
The key can be removed in this position.
“ENGINE STOP” SWITCH
The engine stop switch 1 is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
1
START SWITCH
The start switch 1 is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
1
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.

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GEN
INFO
CONTROL FUNCTIONS
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
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
1
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.

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GEN
INFO
CONTROL FUNCTIONS
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the three positions:
OFF: With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES: This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. FILL THE TANK AT THE
FIRST OPPORTUNITY. BE SURE TO
SET THE LEVER TO “ON” AFTER
REFUELING.
STARTER LEVER (CHOKE)
When cold, the engine requires a richer air/fuel
mixture for starting. A separate starter circuit,
which is controlled by the starter lever 1, sup-
plies this mixture.
Pull the lever out to open the circuit (for start-
ing) and push the lever in to close the circuit.
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.
1
TOOL KIT
Spark plug wrench
Spark plug wrench 1 is used to remove and
install the spark plug.
Screw driver
This tool is used for preventive maintenance
and minor repairs.
1

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GEN
INFO
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
CAUTION:
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.
Recommended fuel:
For USA, AUS and NZ:
Unleaded gasoline only
For CDN and EUROPE:
Regular unleaded gasoline
only
For ZA:
Regular gasoline
Fuel tank capacity:
Total:
4.1 L (0.90 Imp gal, 1.08 US gal)
Reserve:
0.5 L (0.11 lmp gal, 0.13 US gal)
FUEL

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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.
NOTE:
This model is equipped with an ignition cir-
cuit cut-off system. In case of electric start-
ing, the engine can be started only when the
transmission is in neutral.
If the engine fails to start by pushing the start
switch, release the switch, wait a few sec-
onds, and then try again. Each starting
attempt should be as short as possible to
preserve the battery. Do not crank the
engine more than 10 seconds on any one
attempt. If the engine does not start with the
starter motor, try using the kickstarter.
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON”.
3. Shift the transmission into neutral.
4. Operate the starter (choke) and com-
pletely close the throttle grip.
5. Start the engine by pushing the start
switch or by kicking the kickstarter.
6. 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.

SPEC

2 - 1
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: TT-R90ER (USA, CDN, AUS, NZ)
TT-R90E (Europe, ZA)
Model code number: 5HNE (USA)
5HNF (Europe, AUS, NZ, ZA)
5HNG (CDN)
Dimensions:
Overall length 1,525 mm (57.0 in)
Overall width 605 mm (23.8 in)
Overall height 865 mm (34.1 in)
Seat height 625 mm (24.6 in)
Wheelbase 1,040 mm (40.9 in)
Minimum ground clearance 160 mm (6.3 in)
Basic weight:
With oil and full fuel tank 67 kg (147.7 lb)
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 89 cm
3

(5.43 cu.in)
Bore

×

stroke 47.0
×
51.8 mm (1.85
×
2.04 in)
Compression ratio 8.5 : 1
Compression pressure (STD) 1,000 kPa (10 kg/cm
2

, 145 psi) at 1,000 r/min
Starting system Kick and electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil

(For USA and CDN)
At –10 ˚C (10 ˚F) or higher
Å
Yamalube 4 (10W-30) or SAE 10W-30 type
SE/SF motor oil
At 5 ˚C (40 ˚F) or higher
ı
Yamalube 4 (20W-40) or SAE 20W-40 type
SE/SF motor oil
(Except for USA and CDN)
API “SE/SF” or higher grade
0 10 30 50 70 90 110 130
-20 -10 01020
30 40 50
Å
ı
˚F
˚C

GENERAL SPECIFICATIONS