clutch YAMAHA TTR90 2005 Betriebsanleitungen (in German)

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ENG
INSPECTION
Starter clutch
1. Inspect:
Starter idle gear teeth a
Starter drive gear teeth b
Starter wheel gear teeth c
Burrs/chips/roughness/wear →
Replace.
2. Check:
Starter clutch operation
Push the dowel pins to the arrow direc-
tion.
Unsmooth operation → Replace.
Checking steps:
Hold the starter clutch.
When turning the starter wheel gear clock-
wise Å, the starter clutch and the starter
wheel gear should be engaged.
If not, the starter clutch is faulty. Replace
it.
When turning the starter wheel gear coun-
terclockwise ı, it should turn freely.
If not, the starter clutch is faulty. Replace
it.
ı
Å
ASSEMBLY AND INSTALLATION
Starter clutch
1. Install:
Starter clutch 1
1T R..14 Nm (1.4 m · kg, 10 ft · lb)
2. Unloosen the starter clutch assembly by
using the center punch.
CDI MAGNETO AND STARTER CLUTCH (TT-R90E)

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ENGCDI MAGNETO AND STARTER CLUTCH (TT-R90E)
3. Install:
Spring 1
Spring cap 2
Pin 3
4. Install:
Shim 1
Starter wheel gear 2
Starter idle gear 3
Shaft 4
NOTE:
Apply the molybdenum disulfide oil on the
starter wheel gear inner circumference.
Apply the engine oil on the starter idle gear
inner circumference and on the shaft outer
circumference.
12
3
123
5. Install:
Woodruff key 1
Rotor 2
NOTE:
Clean the tapered portion of the crankshaft
and the magneto hub.
When installing the magneto rotor, make
sure the woodruff key is properly seated in
the key way of the crankshaft.
6. Tighten:
Nut (magneto) 1
NOTE:
Tighten the nut (magneto) 1 while holding the
magneto 2 with a sheave holder 3.
7. Install:
Crankcase cover (left)
NOTE:
Pass the starter motor lead 1 and neutral
switch lead 2 into the crankcase cover
groove as shown.
Fasten the starter motor lead with the clamp 3.
Sheave holder:
YS-1880-A/90890-01701
T R..48 Nm (4.8 m · kg, 35 ft · lb)
2
1
1
3

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ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
Extent of removal Order Part name Q’ty Remarks
CRANKCASE SEPARATION
AND CRANKSHAFT REMOVAL
Preparation for removal Seat, fuel tank and rear fender
Exhaust pipe
Air filter case
Carburetor Refer to “CARBURETOR” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Engine guard and drive sprocket
Engine assembly From the chassis.
Cylinder head Refer to “CYLINDER HEAD” section.
Cylinder and piston Refer to “CYLINDER AND PISTON” sec-
tion.
Clutch housing and clutch carrier Refer to “CLUTCH” section.
Kick axle assembly Refer to “KICK AXLE” section.

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ENGCRANKCASE AND CRANKSHAFT
Extent of removal:1 Timing chain removal2 Crankcase separation
3 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
Shift shaft Refer to “SHIFT SHAFT” section.
Oil pump and oil strainer Refer to “OIL PUMP” section.
Rotor for the TT-R90 Refer to “CDI MAGNETO” section for the
TT-R90.
(Rotor and starter clutch for the
TT-R90E)(Refer to “CDI MAGNETO AND
STARTER CLUTCH” section for the
TT-R90E.)
1 Timing chain guide (intake) 1
2 Timing chain 1
3 Clamp 1 TT-R90E
4 Crankcase (right) 1
5 Dowel pin 2
6 Crankshaft 1
7Crankcase (left)
1
1
2
3