brake YAMAHA TTR90 2004 Owner's Manual

5 - 5
CHAS

FRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:

Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
1 1
2
1

EC594000
INSPECTION
EC514100
Wheel
1. Measure:

Wheel runout
Out of limit
→
Repair/replace.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)
Brake lining
1. Inspect:

Brake shoe lining surface
Glazed areas
→
Polish.
Use coarse sand paper.
NOTE:

After polishing, wipe the polished particles with
a cloth.
2. Measure:

Brake shoe lining thickness
Out of specification
→
Replace.
NOTE:

Replace the brake shoes and springs as a set
if either is worn to the limit.
Brake shoe lining thickness
a
:
Standard:
Front: 3.0 mm (0.12 in)
Rear: 4.0 mm (0.16 in)
Limit:
2.0 mm (0.08 in)

5 - 6
CHAS

FRONT FORK
EC550000
FRONT FORK
Extent of removal:
1
Front fork removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK REMOVAL
WARNING

Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Brake cable holder 1
2 Cap bolt 1
3 Adjuster 1 Only loosening.
4 Pinch bolt (under bracket) 1 Only loosening.
5 Front fork 1
1

5 - 9
CHASHANDLEBAR
EC5B0000
HANDLEBAR
TT-R90
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
HANDLEBAR REMOVAL
1“ENGINE STOP” switch 1
2 Brake lever cable 1 Disconnect at the lever side.
3 Brake lever 1
4 Grip cap (lower) 1
5 Grip cap (upper) 1
6 Throttle cable 1 Disconnect at the throttle side.
7 Grip (right) 1
8 Tube guide 1
9 Grip (left) 1
10 Handlebar holder (upper) 2
11 Handlebar 1
12 Handlebar holder (lower) 2
1

5 - 10
CHASHANDLEBAR
TT-R90E
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
HANDLEBAR REMOVAL
1 Main switch 1
2 Start switch 1
3“ENGINE STOP” switch 1
4 Brake lever cable 1 Disconnect at the lever side.
5 Brake lever 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1 Disconnect at the throttle side.
9 Grip (right) 1
10 Tube guide 1
11 Grip (left) 1
12 Handlebar holder (upper) 2
13 Handlebar 1
14 Handlebar holder (lower) 2
1