engine YAMAHA TTR90 2006 Manual PDF

6 - 1
–+ELECELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
TT-R90
EC611000
ELECTRICAL COMPONENTS
1CDI magneto
2CDI unit
3Ignition coil
4Spark plug
5“ENGINE STOP” switch
6Thermo switch
7Carburetor heater
8Rectifier/regulatorCOLOR CODE
B ...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
W ..................... White
EC612000
WIRING DIAGRAM
G/WB/RW/LW/RBr G
RW
WB
Y/R
O
BO
B
B
BY/RY
WY/RB
W
Y
B
GG/W
B/W
B/W
BrB/RWWWY
OO
BBW/LY/RR
W
B
B
B
W/R
Y/R
OFF
RUN
B
Y/R
B
B
Y
Y
1
23
4
5 6
7 8
B/R ................... Black/Red
B/W .................. Black/White
G/W.................. Green/White
W/L .................. White/Blue
W/R .................. White/Red

–+ELEC
ELEKTRISCHE ANLAGE
ELEKTRISCHE BAUTEILE UND
SCHALTPLAN
TT-R90
ELEKTRISCHE BAUTEILE
1Lichtmaschine
2Zündbox
3Zündspule
4Zündkerze
5Motorstoppschalter “ENGINE STOP”
6Thermoschalter
7Vergaserheizung
8Gleichrichter/Regler
FARB-CODIERUNG
B ...................... Schwarz
Br ..................... Braun
G ..................... Grün
O ..................... Orange
R ...................... Rot
W ..................... Weiß
B/R .................. Schwarz/Rot
B/W ................. Schwarz/Weiß
G/W ................. Grün/Weiß
W/L .................. Weiß/Blau
W/R ................. Weiß/Rot
SCHALTPLAN
COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE
ELEKTRISCHE BAUTEILE UND SCHALTPLAN
PARTIE ELECTRIQUE
COMPOSANTS ELECTRIQUES ET
SCHEMA DE CABLAGE
TT-R90
COMPOSANTS ELECTRIQUES
1Volant magnétique CDI
2Boîtier CDI
3Bobine d’allumage
4Bougie
5Coupe-circuit du moteur
6Contacteur thermique
7Réchauffeur de carburateur
8Redresseur/régulateur
CODES DE COULEUR
B .........................Noir
Br ........................Brun
G .........................Vert
O .........................Orange
R .........................Rouge
W ........................Blanc
B/R .....................Noir/rouge
B/W ....................Noir/blanc
G/W ....................Vert/blanc
W/L ....................Blanc/bleu
W/R ....................Blanc/rouge
SCHEMA DE CABLAGE
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–+ELEC
12
3
456
7
0
98
A
B
F
EC
D
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
TT-R90E
EC611000
ELECTRICAL COMPONENTS
1Main switch
2“ENGINE STOP”
switch
3Thermo switch
4Ignition coil
5CDI unit
6Battery
7Rectifier/regulator
8Neutral switch9CDI magneto
0Carburetor heater
AStarter relay
BFuse
CStart switch
DSpark plug
EStarter motor
FStarting circuit cut-off
relayCOLOR CODE
B ...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
EC612000
WIRING DIAGRAM
G/WB/RW/LW/RBr G
RW
B/WBr BRB/WBBrR
B/WB/WBB
BR/WBr B
GG/W
B/W
B/W
BrB/RWWOO
B
BW/LY/RR
W
B
B
R
W/RY/R
OFF RUNB
Y/R
Y
Y
OBO BY/RYB B
Sb
W W
Sb
ON OFF
OFFON
Y
BBY/R
Br
Br
B
B
R
RR
R
B
R/WR/W
R/WR/W
R/W
Sb
Sb
RB
R/WB R
Y/RRB W
B/WB
R/W
R/W
R/W
Sb
9
8
1 B5
4
D
2 3
=A
E 6
C
F 7
B/R ................... Black/Red
B/W .................. Black/White
G/W.................. Green/White
R/W .................. Red/White
W/L .................. White/Blue
W/R .................. White/Red
Y/R ................... Yellow/Red

–+ELEC
TT-R90E
ELEKTRISCHE BAUTEILE
1Zündschloss
2Motorstoppschalter“ENGINE STOP”
3Thermoschalter
4Zündspule
5Zündbox
6Batterie
7Gleichrichter/Regler
8Leerlaufschalter
9Lichtmaschine
0Vergaserheizung
AStarter-Relais
BSicherung
CStarterschalter
DZündkerze
EStartermotor
FAnlasssperrrelais
FARB-CODIERUNG
B ...................... Schwarz
Br ..................... Braun
G ..................... Grün
O ..................... Orange
R ...................... Rot
Sb .................... Himmelblau
W ..................... Weiß
Y ...................... Gelb
B/R .................. Schwarz/Rot
B/W ................. Schwarz/Weiß
G/W ................. Grün/Weiß
R/W ................. Rot/Weiß
W/L .................. Weiß/Blau
W/R ................. Weiß/Rot
Y/R .................. Gelb/Rot
SCHALTPLAN
COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE
ELEKTRISCHE BAUTEILE UND SCHALTPLAN
TT-R90E
COMPOSANTS ELECTRIQUES
1Contacteur à clé
2Coupe-circuit du moteur
3Contacteur thermique
4Bobine d’allumage
5Boîtier CDI
6Batterie
7Redresseur/régulateur
8Contacteur de point mort
9Volant magnétique CDI
0Réchauffeur de carburateur
ARelais de démarreur
BFusible
CContacteur du démarreur
DBougie
EDémarreur
FRelais de coupe-circuit de démarrage
CODES DE COULEUR
B .........................Noir
Br ........................Brun
G .........................Vert
O .........................Orange
R .........................Rouge
Sb........................Bleu ciel
W ........................Blanc
Y .........................Jaune
B/R .....................Noir/rouge
B/W ....................Noir/blanc
G/W ....................Vert/blanc
R/W ....................Rouge/blanc
W/L ....................Blanc/bleu
W/R ....................Blanc/rouge
Y/R .....................Jaune/rouge
SCHEMA DE CABLAGE
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–+ELEC
6 - 3
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Fuel tank
Use the following special tools in this inspection.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754Pocket tester:
YU-3112-C/90890-03112
Spark gap testClean or replace
spark plug.
Check entire ignition
system for connection.Repair or replace.
Check main switch.
(TT-R90E only)Replace.
Check “ENGINE STOP”
switch.Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check CDI magneto. Pickup coil Replace.
Source coil Replace.
Replace CDI unit.
No Spark
OK
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good
No good

–+ELEC
ZÜNDSYSTEM
KONTROLLE
Folgende Prüfschritte dienen zur Diagnose von zündungsbedingten Motorstörungen und von Zünd-
kerzenausfall.
HINWEIS:
Vor der Kontrolle folgende Bauteile demontieren.
1) Sitzbank
2) Kraftstofftank
Folgendes Spezialwerkzeug für die Kontrolle verwenden.
Zündfunkenstrecken-Tester:
YM-34487
Zündungstester:
90890-06754Taschen-Multimeter:
YU-3112-C/90890-03112
Zündfunkenstrecke kontrol-
lieren.Zündkerze reinigen,
ggf. erneuern.
Kabelanschlüsse des
gesamten Zündsystems
kontrollieren.Instand setzen, ggf.
erneuern.
Zündschloss kontrollieren.
(Nur TT-R90E)Erneuern.
Motorstoppschalter
“ENGINE STOP” kontrollie-
ren.Erneuern.
Zündspule kontrollieren.Primärwick-
lungErneuern.
Sekundärwick-
lungErneuern.
Lichtmaschine kontrollieren. Impulsgeber Erneuern.
Spule Erneuern.
Zündbox erneuern.
Kein Funke
In Ordnung
In Ordnung
In Ordnung
In Ordnung
In Ordnung
Funke vorhanden
Nicht in Ordnung
Nicht in Ordnung
Nicht in Ordnung
Nicht in Ordnung
Nicht in Ordnung
Nicht in Ordnung
Nicht in Ordnung
ZÜNDSYSTEM
6 - 3

6 - 4
–+ELECIGNITION SYSTEM
EC622001
SPARK GAP TEST
1. Disconnect the spark plug cap from spark
plug.
2. Connect the dynamic spark tester 1 (igni-
tion checker 2) as shown.
Spark plug cap 3
Spark plug 4
ÈFor USA and CDN
ÉExcept for USA and CDN
3. Kick the kick starter.
4. Check the ignition spark gap.
5. Start engine, and increase spark gap until
misfire occurs. (for USA and CDN only)
Minimum spark gap:
6.0 mm (0.24 in)
È
É
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
MAIN SWITCH INSPECTION (TT-R90E)
1. Inspect:
Main switch continuity
Check for continuity as follows:
Incorrect continuity → Replace. Tester (+)
→ Red lead
1
Tester (–)
→ Brown lead
2 Continuous
Tester (+)
→
Black/White lead
3
Tester (–)
→ Black lead
4 Continuous
R
1Br
2B/W
3B
4Tester selec-
tor position
ON
Ω
× 1
OFF
B/W
BrR
B
1
3
2
4

6 - 5
–+ELECIGNITION SYSTEM
“ENGINE STOP” SWITCH INSPECTION
1. Inspect:
“ENGINE STOP” switch continuity
Not continuous in the “” position → Replace.
Continuous in the “” position → Replace.
ÈTT-R90
ÉTT-R90E
Tester (+) lead
→ Black/White lead
1
Tester (–) lead
→ Black lead
2
B/W
1 B
2 Tester selec-
tor position
Ω
× 1
È
BB/W
1
2É
EC626002
IGNITION COIL INSPECTION
1. Inspect:
Primary coil resistance
Out of specification → Replace.
2. Inspect:
Secondary coil resistance
Out of specification → Replace.
NOTE:
When inspecting the secondary coil resis-
tance, remove the spark plug cap.Tester (+) lead
→ Orange lead
1
Tester (–) lead
→ Black lead
2
Primary coil
resistanceTester selector
position
0.18 ~ 0.28
Ω at
20 °C (68 °F)Ω
× 1
Tester (+) lead
→ Spark plug lead
1
Tester (–) lead
→ Orange lead
2
Secondary coil
resistanceTester selector
position
6.3 ~ 9.5 k
Ω at
20 °C (68 °F)k
Ω
× 1

–+ELEC
MOTORSTOPPSCHALTER “ENGINE STOP”
KONTROLLIEREN
1. Kontrollieren:
Durchgang des Motorstoppschalters
“ENGINE STOP”
Kein Durchgang in Schalterstellung “” →
Erneuern.
Durchgang in Schalterstellung “” → Erneuern.
ÈTT-R90
ÉTT-R90E
ZÜNDSPULE KONTROLLIEREN
1. Kontrollieren:
Primärwicklungs-Widerstand
Nicht nach Vorgabe → Erneuern.
2. Kontrollieren:
Sekundärwicklungs-Widerstand
Nicht nach Vorgabe → Erneuern.
HINWEIS:
Vor der Kontrolle des Sekundärwicklungs-
Widerstandes den Zündkerzenstecker abzie-
hen.Masskabel (+) → Schwarz/Weiß 1
Masskabel (–) → Schwarz 2
B/W
1 B
2 Messgerät-
Wahlschalter
Ω × 1
Masskabel (+) → Orange 1
Masskabel (–) → Schwarz 2
Primärwicklungs-
WiderstandMessgerät-
Wahlschalter
0,18–0,28 Ω bei
20 °C (68 °F)Ω × 1
Masskabel (+) → Zündkabel 1
Masskabel (–) → Orange 2
Sekundärwick-
lungs-WiderstandMessgerät-
Wahlschalter
6,3–9,5 kΩ bei
20 °C (68 °F)kΩ × 1
SYSTEME D’ALLUMAGE
ZÜNDSYSTEM
CONTROLE DU COUPE-CIRCUIT DU
MOTEUR
1. Contrôler:
Continuité du coupe-circuit du moteur
Pas de continuité à la position “” → Remplacer.
Continuité à la position “” → Remplacer.
ÈTT-R90
ÉTT-R90E
CONTROLE DE LA BOBINE D’ALLUMAGE
1. Contrôler:
Résistance de l’enroulement primaire
Hors spécifications → Remplacer.
2. Contrôler:
Résistance de l’enroulement secondaire
Hors spécifications → Remplacer.
N.B.:
Pour contrôler la résistance de l’enroulement
secondaire, déposer le capuchon de bougie. Fil (+) du multimètre →
fil noir/blanc 1

Fil (–) du multimètre →
fil noir 2

B/W
1
B
2
Position du
sélecteur du
multimètre
Ω
×
1
Fil (+) du multimètre →
fil orange 1

Fil (–) du multimètre →
fil noir 2

Résistance de l’en-
roulement primairePosition du sélec-
teur du multimètre
0,18 à 0,28 Ω
à
20°C (68 °F)Ω
×
1
Fil (+) du multimètre →
fil de la bougie 1

Fil (–) du multimètre →
fil orange 2

Résistance de l’en-
roulement secondairePosition du sélec-
teur du multimètre
6,3 à 9,5 kΩ
à
20°C (68 °F)kΩ
×
1
6 - 5

6 - 7
–+ELEC
ELECTRIC STARTING SYSTEM
(TT-R90E)
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the main switch is set to “ON”, the starter
motor can only operate if the following condi-
tion is met:
The transmission is in neutral (the neutral
switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when this condi-
tion has not been met. In this instance, the
starting circuit cut-off relay is open so current
cannot reach the starter motor. When the
above condition has been met the starting cir-
cuit cut-off relay is closed and the engine can
be started by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
1Battery
2Main fuse
3Main switch
4Start switch
5Starting circuit cut-off relay
6Neutral switch
7Starter relay
8Starter motor
12
M
3
7
54
6 8
ELECTRIC STARTING SYSTEM (TT-R90E)