wheel YAMAHA TTR90 2006 Betriebsanleitungen (in German)

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 (TT-R90) ........................4-39
CDI MAGNETO AND
STARTER CLUTCH (TT-R90E) ...............4-41
CRANKCASE AND CRANKSHAFT ........4-45
SHIFT FORK, SHIFT CAM AND
TRANSMISSION ......................................4-48
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL .......5-1
FRONT FORK ..........................................5-10
HANDLEBAR ...........................................5-13
STEERING ...............................................5-18
SWINGARM .............................................5-20
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM ....................................6-1
IGNITION SYSTEM ....................................6-3
ELECTRIC STARTING SYSTEM
(TT-R90E) ..................................................6-7
CHARGING SYSTEM (TT-R90E) ............6-15
CARBURETOR HEATING SYSTEM .......6-17
MAINTENANCE RECORD ......................6-21

GEN
INFO
1 - 7
SPECIAL TOOLS
YM-1312-A, 90890-01312 Fuel 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

GEN
INFO
1 - 8
SPECIAL TOOLS
YU-33270-B, 90890-01362 Flywheel puller
This tool is used to remove the rotor.YU-33270-B 90890-01362
ACC-QUICK-GS-KT
90890-85505Quick gasket
®
YAMAHA Bond No. 1215
This sealant (Bond) is used for crankcase mating sur-
face, etc.ACC-QUICK-GS-KT 90890-85505
Part number Tool name/How to use Illustration

GEN
INFO
1 - 14
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid combi-
nation cleaner-waxes, as they may contain
abrasives.
9. After completing the above, start the
engine and allow it to idle for several min-
utes.
EC182001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the car-
buretor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do not
apply oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the
machine is stored.

SPEC
2 - 1
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: TT-R90V (CDN, AUS, NZ)
TT-R90 (Europe, ZA)
TT-R90EV (USA, CDN, AUS, NZ)
TT-R90E (Europe, ZA)
Model code number: TT-R90:
5HNW (Europe, AUS, NZ, ZA)
5HNX (CDN)
TT-R90E:
3P21 (USA)
3P22 (Europe, AUS, NZ, ZA)
3P23 (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)
Dry weight:
Without oil and fuel (TT-R90) 60.0 kg (132.3 lb)
(TT-R90E) 63.0 kg (138.9 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 (TT-R90) Kick starter
(TT-R90E) Kick and electric starter
Lubrication system: Wet sump
GENERAL SPECIFICATIONS

SPEC
2 - 3 Transmission:
Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 35/14 (2.500)
Transmission type Constant mesh, 3-speed
Operation Left foot operation
Gear ratio: 1st 37/13 (2.846)
2nd 33/19 (1.736)
3rd 28/23 (1.217)
Chassis:
Frame type Steel tube backbone
Caster angle 24.83°
Trail 56.0 mm (2.2 in)
Tire:
Type With tube
Size (front) 2.50-14 4PR
Size (rear) 3.00-12 4PR
Manufacturer (front and rear) CHENG SHIN
Type (front and rear) KNOBBY
Tire pressure (front and rear) 100 kPa (1.00 kgf/cm
2, 14.5 psi)
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 95 mm (3.74 in)
Electrical:
Ignition system CDI
Generator system (TT-R90E) CDI magneto
Battery type (TT-R90E) GT4B-5
Battery voltage/capacity (TT-R90E) 12 V/2.5 AH
Specific gravity (TT-R90E) 1.350
GENERAL SPECIFICATIONS

SPEC
2 - 11 CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Angular bearing ----
Front suspension:
Front fork travel 110 mm (4.33 in) ----
Fork spring free length 425.1 mm (16.74 in) 417 mm (16.4 in)
Fork spring fitting length 415.1 mm (16.34 in) ----
Spring rate, STD K = 3.4 N/mm
(0.35 kg/mm, 19.41 lb/in)----
Optional spring/spacer No ----
Oil capacity 64 cm
3
(2.26 Imp oz, 2.16 US oz) ----
Oil level 185 mm (7.28 in) ----
Oil grade Fork oil 15W or equivalent ----
Rear suspension:
Shock absorber travel 48 mm (1.89 in) ----
Spring free length 169 mm (6.65 in) ----
Fitting length 165 mm (6.5 in) ----
Spring rate, STD K = 45.6 N/mm
(4.65 kg/mm, 260 lb/in)----
Optional spring No ----
Enclosed gas pressure 2,000 kPa
(20 kg/cm
2, 290 psi)----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)
Side clearance ---- 0.3 mm (0.01 in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 14 × 1.40/steel ----
Rear rim size/material 12 × 1.60/steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID420(I)/DAIDO ----
Number of links 86 links ----
Chain slack 40 ~ 53 mm (1.6 ~ 2.1 in) ----
Chain length (15 links) ---- 194.3 mm
(7.65 in)
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m  kg, 27 ft  lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 1 Nm (0.1 m  kg, 0.7 ft  lb).
-marked portion shall be checked for torque tightening after break-in or before each ride.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Engine mounting:
Engine and frame (front-upper) M8 × 1.25 1 30 3.0 22
Engine and frame (rear-upper) M8 × 1.25 1 26 2.6 19
Engine and frame (rear-lower) M10 × 1.25 1 48 4.8 35
Starter cable and frame M11 × 1.25 1 1 0.1 0.7
Pivot shaft and nut M10 × 1.25 1 30 3.0 22
Handle crown and steering shaft M10 × 1.25 1 40 4.0 29
Front fork cap bolt M20 × 1.0 2 40 4.0 29
Under bracket and front fork M10 × 1.25 2 33 3.3 24
Damper rod bolt M8 × 1.25 2 20 2.0 14
Handle crown and handlebar holder (lower) M10 × 1.25 2 40 4.0 29
Handlebar holder (upper)(TT-R90) M6 × 1.0 4 13 1.3 9.4
(TT-R90E) M8 × 1.25 4 23 2.3 17
Front brake cable holder and front fork M6 × 1.0 2 7 0.7 5.1
Steering ring nut M25 1 Refer to NOTE.
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and frame M6 × 1.0 2 7 0.7 5.1
Grab bar and frame M6 × 1.0 4 13 1.3 9.4
Brake lever mounting (bolt) M6 × 1.0 1 3 0.3 2.2
Brake lever mounting (nut) M6 × 1.0 1 4 0.4 2.9
Front brake camshaft lever and camshaft M6 × 1.0 1 7 0.7 5.1
Rear brake camshaft lever and camshaft M6 × 1.0 1 7 0.7 5.1
Front wheel axle nut M10 × 1.25 1 35 3.5 25
Rear brake shoe plate tension bar M8 × 1.25 2 26 2.6 19
Wheel drive hub and driven sprocket M8 × 1.25 4 25 2.5 18
Rear wheel axle nut M12 × 1.25 1 60 6.0 43
Wheel nipple (spoke)—64 2 0.2 1.4
Drive chain guard M5 × 0.8 2 4 0.4 2.9
Drive chain support M5 × 0.8 3 4 0.4 2.9
Chain puller locknut M6 × 1.0 2 7 0.7 5.1
Footrest and frame M8 × 1.25 2 30 3.0 22
Battery box (TT-R90E) M6 × 1.0 3 5 0.5 3.6
MAINTENANCE SPECIFICATIONS

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
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.
NOTE:
From 18 months or 210 hours, repeat the maintenance intervals starting from 6 months or
90 hours.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No. ITEMCHECKS AND
MAINTENANCE JOBSWHICH-
EVER
COMES
FIRSTINITIAL EVERY
month 1 6 12
hours 30 90 150
1 * Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.√
√
2 Spark plugCheck condition.
Adjust gap and clean.√
√
3 * Valve clearanceCheck and adjust valve clearance when engine is
cold.√
4 * Air filter elementClean with solvent.
Replace if necessary.√
√
5 * Breather systemCheck ventilation hose for cracks or damage.
Replace if necessary.√
√
√
6 * CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.√
√
√
7 Exhaust systemCheck for leakage.
Tighten if necessary.
Replace gasket if necessary.√
√
8 Engine oil Change (warm engine before draining).
√
√
√
9 ClutchCheck operation.
Adjust or replace cable.√
√
√
10 * Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes
if necessary.√
√
√
11 * Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes
if necessary.√
√
√
12 * WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√
√
√
13 * TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√
√
14 * Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√
√
15 * SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap based grease.√
√
√
16 Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain.Every ride
3

3 - 3
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condi-
tion.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Brake Check operation/adjustment. P3-12
Engine oil Change oil as required. P3-6 ~ 8
Drive chain Check alignment/adjustment/lubrication. P3-13 ~ 15
Spark plug Check color/condition. P3-23
Throttle Check for proper throttle cable operation. P3-4
Air filter Foam type – must be clean and damp oil always P3-4 ~ 5
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P3-17 ~ 20
Fittings/fasteners Check all – tighten as necessary. P2-13