brake YAMAHA TTR90 2006 Owner's Manual

5 - 3
CHASFRONT 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
2Cotter 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
2
1
3

5 - 4
CHASFRONT 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
2
3

5 - 5
CHASFRONT 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.
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.
Wheel runout limit:
Radial
1: 2.0 mm (0.08 in)
Lateral
2: 2.0 mm (0.08 in)
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
ASSEMBLY AND INSTALLATION
1. Install:
Brake camshaft lever 1
NOTE:
Install the brake camshaft lever in relation to
the punch mark a as shown.
ÈFront
ÉRear
1
1a
È
a 1
1
É
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
Springs 1
Brake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New
FRONT WHEEL AND REAR WHEEL

5 - 7
CHASFRONT WHEEL AND REAR WHEEL
Front wheel
1. Install:
Wheel bearing 1
Spacer 2
Wheel bearing 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the
wheel bearing and oil seal lip when installing.
Install the wheel bearing so that the enclosed
side is facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of wheel bearing shall be installed
first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
Brake shoe plate assembly
Collar set 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
New
3. Install:
Front wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the front fork outer
tube.
4. Install:
Brake cable
NOTE:
Brake camshaft lever side of brake cable shall
be installed first.

5 - 8
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
Brake cable holder 1
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
6. Adjust:
Brake lever free play
Refer to “FRONT BRAKE ADJUST-
MENT” section in the CHAPTER 3.
Wheel drive hub assembly
1. Install:
Bearing 1
Oil seal 2
Collar 3
Sprocket shaft 4
Driven sprocket 5
Lock washers 6
Nuts 7
Bolts 8
NOTE:
Install the oil seal with its manufacture’s
marks or numbers facing outward.
Tighten the bolts in stage, using a crisscross
pattern.
Bend the lock washer tab.
New
New
T R..25 Nm (2.5 m · kg, 18 ft · lb)

5 - 10
CHASFRONT 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 - 13
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.
3Brake 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 Refer to “REMOVAL POINTS”.
8 Tube guide 1
9 Grip (left) 1 Refer to “REMOVAL POINTS”.
10 Handlebar holder (upper) 2
11 Handlebar 1
12 Handlebar holder (lower) 2
1

5 - 14
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.
5Brake 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 Refer to “REMOVAL POINTS”.
10 Tube guide 1
11 Grip (left) 1 Refer to “REMOVAL POINTS”.
12 Handlebar holder (upper) 2
13 Handlebar 1
14 Handlebar holder (lower) 2
1

5 - 17
CHASHANDLEBAR
5. Install:
Brake lever holder 1
Brake cable 2
NOTE:
Apply the lithium soap base grease on the
front brake cable end.
The brake lever holder should be installed
according to the dimensions as shown.
ÈTT-R90
ÉTT-R90E
1 2
LS
5mm
(0.2 in)
È
LS
Zero mm
(Zero in)1 2
É
6. Install:
Engine stop switch 1
NOTE:
Align the tab a on the engine stop switch
holder with the hole b in the handlebar.
a b
1