warning YAMAHA TTR90 2006 Owner's Manual

5 - 16
CHASHANDLEBAR
2. Install:
Grip (left) 1
Apply the adhesive to the handlebar 2.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.
Install the grip (left) to the handlebar so that
the line b between the two arrow marks
faces straight upward.
3. Install:
Grip (right) 1
Collar 2
Apply the adhesive on the tube guide 3.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the tube guide surface a
with a lacquer thinner.
Align the mating mark b on the grip (right)
with the slot c in the tube guide.
cb
4. Install:
Screws (throttle housing)
WARNING
After tightening the screws, check that the
throttle grip
1 moves smoothly. If it does
not, retighten the bolts for adjustment.

5 - 18
CHASSTEERING
EC560000
STEERING
LS
LS
T R..TIGHTENING STEPS:
Tighten ring nut.
38 Nm (3.8 m  kg, 27 ft  Ib)
Loosen it completely.
Retighten it.
1 Nm (0.1 m  kg, 0.7 ft  Ib)
T R..40 Nm (4.0 m  kg, 29 ft  Ib)
5 9681076 43
21
Extent of removal:
1 Under bracket removal
2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING 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 fork Refer to “FRONT FORK” section.
1 Steering stem bolt 1
2 Handle crown 1
3 Ring nut 1 Use special tool.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
4 Ball race cover 1
5 Under bracket 1
6 Bearing inner race 2
7 Upper bearing ball 19
8 Lower bearing ball 16
9 Dust seal 1
10 Bearing outer race 2
2
1

5 - 19
CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long rod
2 and the hammer.
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
STEERING

5 - 20
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:
1 Swingarm removal
2 Rear shock absorber removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM 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.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Rear fender
Drive chain
1Cotter pin 2
2Pin 2
3 Rear shock absorber 1
4 Pivot shaft 1 Hold the swingarm.
5 Swing arm 1
6 Drive chain guide 1
7 Drive chain guard 1
8 Drive chain support 1
2
1

6 - 9
–+ELEC
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
STARTER MOTOR OPERATION
1. Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Not operate → Repair or replace the
starter motor.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the a battery lead, otherwise the
jumper lead may burn.
This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.
STARTING CIRCUIT CUT-OFF RELAY
INSPECTION
1. Remove:
Starting circuit cut-off relay
2. Inspect:
Starting circuit cut-off relay conduct
Use 12 V battery.
Battery (+) lead → Red/White lead 1
Battery (–) lead → Sky blue lead 2
Tester (+) lead → Red/White lead 3
Tester (–) lead → Red/White lead 4
R/W
3 R/W
4 Tester selec-
tor position
Connected
to battery
Ω × 1
Not
connected
to battery
2 4
3
1
ELECTRIC STARTING SYSTEM (TT-R90E)

6 - 19
–+ELEC
ÊThe thermo switch circuit is open.
ËThe thermo switch circuit is closed.
Test step Water temperature Continuity
1TT-R90:
Less than 23 ± 3 °C
(73.4 ± 5.4 °F)
TT-R90E:
Less than 16 ± 3 °C
(60.8 ± 5.4 °F)YES
2TT-R90:
More than 23 ± 3 °C
(73.4 ± 5.4 °F)
TT-R90E:
More than 16 ± 3 °C
(60.8 ± 5.4 °F)NO
3TT-R90:
More than 12 ± 4 °C
(53.6 ± 7.2 °F)
TT-R90E:
More than 11 ± 3 °C
(51.8 ± 5.4 °F)NO
4TT-R90:
Less than 12 ± 4 °C
(53.6 ± 7.2 °F)
TT-R90E:
Less than 11 ± 3 °C
(51.8 ± 5.4 °F)YES
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
WARNING
Handle the thermo switch with special
care.
Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
Check the thermo switch operation.
È
É
CARBURETOR HEATING SYSTEM