brake YAMAHA TTR90 2006 User Guide

2 - 21
SPECCABLE ROUTING DIAGRAM
TT-R90E
1Crankcase breather hose
2CDI magneto lead
3Wire harness
4Thermo switch
5Thermo switch lead
6CDI unit lead
7Spark plug lead
8Starter cable
9Starter relay lead
0Starter motor leadAStarter motor
BThrottle cable
CBrake cable
DEngine stop switch lead
EMain switch lead
FStart switch lead
ÈPass the spark plug lead
through the lead guide.ÉMake sure that the starter
cable does not contact the
engine bracket.
ÊFasten the engine stop lead
with the plastic bands.
ËPass the brake cable through
the cable guide.
ÌFasten the start switch lead
with the plastic bands.
30 ~ 40 mm
(1.18 ~ 1.57 in)
A
20 ~30 mm
(0.79 ~ 1.18 in)B
C
D
E Ì
F
ËËÊ A875 4
6 3
2
1
È
É
A
0
9
10 ~ 20 mm
(0.39 ~ 0.79 in)

2 - 22
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
QRÑ
8
E
H
Ô 2 3 4
6
5
4
3
2
1
J
I
H
G
F
E
D
CBA 0 Í 9 8 Ë K 7
S
W U
V
A
0
Ú T
99
QP
PT
9 Ò
Ó
Õ Ö
Ê É
È
Ï
Ø
Ù
E
GGA
P
O
NML 9
Ð
9
Î
Û
Ý
25 mm (1.0 in)
×
Ì
35 ~ 45 mm
(1.38 ~ 1.77 in)
30 ~ 40 mm
(1.18 ~ 1.57 in)
Ü

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 - 2
INSP
ADJ
MAINTENANCE INTERVALS
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
17 * Steering bearingsCheck bearing assemblies for looseness.
Lubricate with lithium soap based grease every or
120 hours or 12 months (whichever comes first).√
√
18Brake and clutch
lever pivot shaftsApply lithium soap based grease lightly.
√
√
√
19Brake pedal pivot
shaftApply lithium soap based grease lightly.
√
√
√
20 Sidestand pivotCheck operation.
Apply lithium soap based grease lightly.√
√
21 * Front forkCheck operation and for oil leakage.
Replace if necessary.√
√
22 *Shock absorber
assemblyCheck operation and for oil leakage.
Replace if necessary.√
√
23 * Control cablesApply Yamaha chain and cable lube or engine oil
10W-30 thoroughly.√
√
√
24 *Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√
√
√
25 * Chassis fastenersCheck all chassis fitting and fasteners.
Correct if necessary.√
√
√
26Battery (TT-R90E
only)Check terminal for looseness and corrosion.
√ No. ITEMCHECKS AND
MAINTENANCE JOBSWHICH-
EVER
COMES
FIRSTINITIAL EVERY
month 1 6 12
hours 30 90 150


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

3 - 12
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 - 15
INSP
ADJ
FRONT FORK INSPECTION
3. Adjust:
Drive chain slack
Drive chain slack adjustment steps:
Loosen the wheel axle nut 1 and locknuts
2.
Adjust chain slack by turning the adjusters
3.
To tighten
→ Turn adjuster
3 clockwise.
To loosen
→ Turn adjuster
3 counter-
clockwise and push wheel forward.
Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of chain
puller alignment.)
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
CAUTION:
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
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)
13 a2
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.

3 - 22
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 endÈUse Yamaha cable lube or equivalent on these
areas.
ÉUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÊLubricate 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
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
9 Bearing 2 Refer to “REMOVAL POINTS”.
2
13
3
FRONT WHEEL AND REAR WHEEL

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