brake YAMAHA TTR90 2005 User Guide

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SPECCABLE ROUTING DIAGRAM
1Clamp
2Engine stop switch lead
3Main switch lead
4Start switch lead
5Brake cable
6Throttle cable
7Fuel tank breather hose
8Ignition coil
9Wire harness
0Starter relay
AStarter motor leadBCrankcase breather hose
CStarter motor lead
DNeutral switch lead
ECDI magneto lead
FCDI unit
GFuel 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
◊
25 mm (1.0 in)
∏
‰
35 ~ 45 mm
(1.38 ~ 1.77 in)
30 ~ 40 mm
(1.18 ~ 1.57 in)
Ë

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS/
PERIODIC MAINTENANCE AND LUBRICATION
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
PERIODIC MAINTENANCE AND LUBRICATION
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
* Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
* ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace if necessary.
* CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
* Front brakeCheck operation.
Adjust brake lever free play and replace brake
shoes if necessary.Every ride
* Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
* WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
* TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
* Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
* SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap base grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
* Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.
3

3 - 2
INSP
ADJ

PRE-OPERATION INSPECTION AND MAINTENANCE
*: Since these items requires special tools data and technical skills, they should be serviced.
*
1

: For USA
SERVICE NOTES:

No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every
0.5 ~ 1.0 hour. If unit is subjected to extremely hard usage and wet weather riding, chain
must be checked constantly. See “Lubrication Intervals” for additional details.
No. 2. AIR FILTER: Remove and clean filter every 20 ~ 40 hours.
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
* Chassis fastenersMake sure that all nuts, bolts and screws are
properly tightened.
Tighten if necessary.
SidestandCheck operation.
Lubricate and repair if necessary.
* Spark arrester
*
1

Clean.
* Front forkCheck operation and for oil leakage.
Correct accordingly.
*Rear shock
absorber assemblyCheck operation and shock absorber for oil
leakage.
Replace shock absorber assembly if necessary.
Battery
(TT-R90E only)Check terminal for corrosion.
Clean if necessary.
Item Routine Page
Brake Check operation/adjustment. P3-11
Engine oil Change oil as required. P3-5 ~ 7
Drive chain Check alignment/adjustment/lubrication. P3-12 ~ 13
Spark plug Check color/condition. P3-20
Throttle Check for proper throttle cable operation. P3-3
Air filter Foam type – must be clean and damp oil always P3-3 ~ 4
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P3-14 ~ 15
Fittings/fasteners Check all – tighten as necessary. P2-13 Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
3

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INSP
ADJCHASSIS/FRONT BRAKE ADJUSTMENT/
REAR BRAKE ADJUSTMENT
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever free play a
Out of specification → Adjust.
Free play (brake lever):
10 ~ 20 mm (0.39 ~ 0.79 in)
(at brake lever end)
a
21
2. Adjust:
Brake lever free play
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal free play a
Out of specification → Adjust.
2. Adjust:
Brake pedal free play Adjustment steps:
Loosen the locknuts 1.
Turn the adjusters 2 in or out until the
specified free play is obtained.
Turning in: Free play is increased.
Turning out: Free play is decreased.
Tighten the locknuts.
CAUTION:
Make sure that there is no brake drag
after adjusting the front brake lever free
play.
Free play:
10 ~ 20 mm (0.39 ~ 0.79 in)
Adjustment steps:
Turn the adjuster 1 in or out until the
specified free play is obtained.
Turning in: Free play is decreased.
Turning out: Free play is increased.
CAUTION:
Make sure that the brake does not drag
after adjusting it.
1
a

3 - 13
INSP
ADJFRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT
Tighten the wheel axle nut while pushing
down the drive chain.
T R..
Axle nut:
60 Nm (6.0 m • kg, 43 ft • lb)
Tighten the locknuts.
T R..
Locknut:
7 Nm (0.7 m • kg, 5.1 ft • lb)
EC36C000
FRONT FORK INSPECTION
1. Inspect:
Front fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage → Repair
or replace.
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
Swingarm smooth action
Abnormal noise/unsmooth action →
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage → Replace.
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the
suitable stand under the engine.
2. Remove:
Rear shock absorber
Refer to “SWINGARM” section in the
CHAPTER 5.
3. Remove:
Spring guide 1
NOTE:
While compressing the spring, remove the
spring guide.

3 - 19
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Brake lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Brake cable endÅUse Yamaha cable lube or equivalent on these
areas.
ıUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÇLubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC
78

5 - 1
CHAS

EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL AND FRONT BRAKE
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL 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.
1 Bolt (brake cable holder) 1 Only loosening.
2 Brake cable 1 Disconnect at the lever side.
3 Wheel axle nut 1
4 Front wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9Bearing
2Refer to “REMOVAL POINTS”.
2
31
3

5 - 2
CHAS

Extent of removal Order Part name Q’ty Remarks
10 Brake shoe 2
11 Brake camshaft lever 1
12 Brake camshaft 1
3

FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS

FRONT WHEEL AND REAR WHEEL
REAR WHEEL AND REAR BRAKE
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL 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.
1 Brake rod 1
2 Cotter pin 1
3 Nut (tension bar) 1
4 Bolt (tension bar) 1
5 Wheel axle nut 1
6 Rear wheel axle 1
7 Drive chain puller 2
8 Rear wheel 1
9 Collar (right) 1
10 Brake shoe plate assembly 1
231

5 - 4
CHAS

FRONT WHEEL AND REAR WHEEL
Extent of removal Order Part name Q’ty Remarks
11 Collar (left) 1
12 Wheel drive hub assembly 1
13 Bearing 2 Refer to “REMOVAL POINTS”.
14 Brake shoe 2
15 Brake camshaft lever 1
16 Brake camshaft 1
3
2