ignition YAMAHA TTR90 2003 Owners Manual

CHAPTER 4
ENGINE
CARBURETOR
..........................................4-1
CYLINDER HEAD
......................................4-8
CAMSHAFT AND ROCKER ARMS
........4-13
VALVES AND VALVE SPRINGS
............4-16
CYLINDER AND PISTON
........................4-21
CLUTCH
...................................................4-27
KICK AXLE
..............................................4-33
SHIFT SHAFT
..........................................4-34
OIL PUMP
................................................4-36
CDI MAGNETO
AND STARTER CLUTCH
........................4-39
CRANKCASE AND CRANKSHAFT
........4-43
SHIFT FORK, SHIFT CAM
AND TRANSMISSION
.............................4-46
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL
.......5-1
FRONT FORK
............................................5-6
HANDLEBAR
.............................................5-9
STEERING
...............................................5-10
SWINGARM
.............................................5-11
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM
...........................6-1
IGNITION SYSTEM
....................................6-2
ELECTRIC STARTING SYSTEM
..............6-6
CHARGING SYSTEM
..............................6-14
CARBURETOR HEATING SYSTEM
.......6-16
MAINTENANCE RECORD
......................6-19

1 - 7
GEN
INFO
SPECIAL TOOLS
YM-1312-A, 90890-01312Fuel level gauge
This gauge is used to measure the fuel level in the
float chamber.YM-1312-A 90890-01312
YM-1326, 90890-01326 T-handle
This tool is used for holding the damper rod holder
when removing or installing the damper rod holder.YM-1326 90890-01326
90890-01186 Fork seal driver attachment
This tool is used to installing the oil seal.90890-01186
YM-8035, 90890-01311 Valve adjusting tool
This tool is necessary for adjusting valve clearance.YM-8035 90890-01311
YM-33963, 90890-01184 Fork seal driver weight
This tool is used to installing the oil seal.YM-33963 90890-01184
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
YM-33975, 90890-01403 Ring nut wrench
This tool is used when tighten the steering ring nut to
specification.YM-33975 90890-01403
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
YS-1880-A, 90890-01701 Sheave holder
This tool is used for when loosening or tightening the
flywheel magneto securing nut.YS-1880-A 90890-01701
Part number Tool name/How to use Illustration

1 - 13
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 - 3
Brake:
Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 110 mm (4.33 in)
Rear wheel travel 93 mm (3.66 in)
Electrical:
Ignition system CDI
Generator system CDI magneto
Battery type GT4B-5
Battery voltage/capacity 12 V/2.5 AH
Specific gravity 1.350
GENERAL SPECIFICATIONS

SPEC
2 - 14
EC212300
ELECTRICAL
Item Standard Limit
CDI:
Magneto-model/manufacturer F5HN/YAMAHA ----
Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C (68 ˚F)
(Brown – Green)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(Red – White)----
CDI unit-model/manufacturer 5HN/YAMAHA ----
Ignition coil:
Model/manufacturer 2JN-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 ˚C (68 ˚F) ----
Spark plug cap:
Type Resin ----
Resistance 10 kΩ at 20 ˚C (68 ˚F) ----
Charging system:
System type CDI magneto ----
Model/manufacturer F5HN/YAMAHA ----
Normal output 14 V/100 W at 5,000 r/min ----
Lighting coil 1 resistance (color) 0.64 ~ 0.96 Ω at 20 ˚C (68 ˚F)
(White – Black)----
Lighting coil 2 resistance (color) 0.52 ~ 0.78 Ω at 20 ˚C (68 ˚F)
(Yellow – Black)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH620B-12/SHINDENGEN ----
No-load regulated voltage 14.0 ~ 15.0 V ----
Rectifier capacity 8 A ----
Electric starting system:
Type Constant mesh
Starter motor:
Model/manufacturer 5HN/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.018 ~ 0.022 Ω at 20 ˚C (68 ˚F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Brush quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)3.92 N
(400g,
14.1 oz)
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in) ----
MAINTENANCE SPECIFICATIONS

2 - 18
SPEC

CABLE ROUTING DIAGRAM
1
Clamp
2
Engine stop switch lead
3
Main switch lead
4
Start switch lead
5
Brake cable
6
Throttle cable
7
Fuel tank breather hose
8
Ignition coil
9
Wire harness
0
Starter relay
A
Starter motor lead
B
Crankcase breather hose
C
Starter motor lead
D
Neutral switch lead
E
CDI magneto lead
F
CDI unit
G
Fuel overflow hose
HSpark plug lead
IFuel hose
JCarburetor heater lead
KCarburetor breather hose
LCarburetor heater couplerMCDI magneto coupler
NCDI unit coupler
OCDI unit connector
PCDI unit lead
QThermo switch lead
RThermo switch
SStarting circuit cut-off relay
TStarting circuit cut-off relay lead
URectifier/regulator lead
VRectifier/regulator
WStarter relay lead
A AA
C C
D
B
B B
BF FF
EE
D
A - AB - BE - E
C
F - FG - GD
KK
QRÔ
8
E
H
˜ 2 3 4
6
5
4
3
2
1
J
I
H
G
F
E
D
CBA 0 Ï 9 8 Î K 7
S
W U
V
A
0
Í T 99
QP
PT
9 
Ò
ˆ Ø
Ç ı
Å
Ó
Œ
Â
E
GGA
P
O
NML 9
È
9
Ì
Ê
Ë
25 mm (1.0 in)
∏
‰

3 - 26
INSP
ADJ
FUSE INSPECTION
3. Replace:
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
Rear fender
Seat Replacement steps:
Set the main switch to “OFF”.
Install a new fuse of the correct amperage.
Set on the switches to verify if the electri-
cal circuit is operational.
If the fuse immediately blows again, check
the electrical circuit.
ItemsAmperage
ratingQ’ty
Main fuse 10 A 1

4 - 6
ENGCARBURETOR
EC464600
Float
1. Inspect:
Float 1
Damage → Replace.
ASSEMBLY AND INSTALLATION
Carburetor
1. Install:
Pilot air screw 1
Note the following installation points:
Screw in the pilot air screw until it is lightly
seated.
Back out it by the specified number of
turns.
Pilot air screw:
1-3/4 turns out
2. Install:
Throttle valve 1
Starter 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.

6 - 1
–+ELEC

12
3
456
7
0
98

A
B
F
EC
D

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
Main switch
2
“ENGINE STOP”
switch
3
Thermo switch
4
Ignition coil
5
CDI unit
6
Battery
7
Rectifier/regulator
8
Neutral switch
9
CDI magneto
0
Carburetor heater
A
Starter relay
B
Fuse
C
Start switch
D
Spark plug
E
Starter motor
F
Starting circuit cut-off
relay
COLOR CODE
B ...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
EC612000
WIRING DIAGRAM
G/WB/RW/LW/RBr G
RW
B/WBr BRB/WBBrR
B/WB BB
BR/WBr B
GG/W
B/W
B/W
BrB/RWWOO
B
BW/LY/RR
W
B
B
R
W/RY/R
OFF RUNB
Y/R
Y
Y
OBO BY/RYB B
Sb
W W
Sb
ON OFF
OFFON
Y
BB
Y/R
Br
Br
B
B
R
RR
R
B
R/WR/W
R/WR/W
R/W
Sb
Sb
RB
R/WB R
Y/RRB W
B/WB
R/W
R/W
R/W
Sb
9
8
1 B5
4
D
2 3
=A
E 6
C
F 7

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

–+ELEC

6 - 2
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
NOTE:


Remove the following parts before inspection.
1) Seat
2) Fuel tank

Use the following special tools in this inspection.
Spark gap testClean or replace
spark plug.
Check entire ignition
system for connection.Repair or replace.
Check main switch. Replace.
Check “ENGINE STOP”
switch.Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check CDI magneto. Pickup coil Replace.
Source coil Replace.
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
No Spark
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good
OK
No good