oil YAMAHA TTR90 2006 Owners Manual

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 6 are designed as
thumb tabs to indicate the chapter’s number
and content.
1General information
2Specifications
3Regular inspection and adjustments
4Engine
5Chassis
6Electrical
Illustrated symbols 7 to D are used to identify
the specifications appearing in the text.
7With engine mounted
8Special tool
9Filling fluid
0Lubricant
ATightening
BSpecified value, Service limit
CEngine speed
DResistance (
Ω), Voltage (V), Electric current (A)
Illustrated symbols E to H in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
EApply engine oil
FApply molybdenum disulfide oil
GApply lightweight lithium-soap base grease
HApply molybdenum disulfide grease
Illustrated symbols I to J in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
IApply locking agent (LOCTITE®)
JUse new one 12
34
56
78
90
AB
CD
E
F
G
H
IJ
GEN
INFOSPEC
INSP
ADJ
ENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

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

1 - 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil
the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.

GEN
INFO
1 - 6
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-” or “ACC-”.
For others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1083-A
90890-01084
90890-01085Slide hammer set
Weight
Slide hammer bolt
These tools are used when removing or installing the
rocker arm shafts.YU-1083-A 90890-01084
90890-01085
YU-1268, 90890-01268 Ring nut wrench
This tool is used when loosen the steering ring nut to
specification.YU-1268 90890-01268
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YU-8036-B
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-B 90890-03113
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-1300
90890-01294Damper rod holder set
Damper rod holder
Use this tool to remove and install the damper rod.YM-1300 90890-01294
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.YU-1304 90890-01304

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 - 13
STARTING AND OPERATION
STARTING AND OPERATION
CAUTION:
Prior to operating the machine, perform
steps listed in pre-operation check list.
WARNING
Never start your engine or let it run for any
length of time in a closed area. The exhaust
fumes are poisonous and can cause loss of
consciousness and death within a short
time. Always operate your machine in an
area with adequate ventilation.
STARTING A COLD ENGINE
TT-R90
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
1. Turn the fuel cock to “ON”.
2. Operate the starter (choke) and completely
close the throttle grip.
3. Slide the “ENGINE STOP” switch to the
“”.
4. Kick the kick starter with full strength to
start the engine.
5. After the engine starts, warm up for one or
two minutes. Make sure the stater (choke)
is returned to the original position before
riding.
TT-R90E
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
NOTE:
This model is equipped with an ignition cir-
cuit cut-off system. In case of electric start-
ing, the engine can be started only when the
transmission is in neutral.
If the engine fails to start by pushing the start
switch, release the switch, wait a few sec-
onds, and then try again. Each starting
attempt should be as short as possible to
preserve the battery. Do not crank the
engine more than 10 seconds on any one
attempt. If the engine does not start with the
starter motor, try using the kickstarter.1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON”.
3. Shift the transmission into neutral.
4. Operate the starter (choke) and completely
close the throttle grip.
5. Slide the “ENGINE STOP” switch to the
“”.
6. Start the engine by pushing the start switch
or by kicking the kickstarter.
7. After the engine starts, warm up for one or
two minutes. Make sure the stater (choke) is
returned to the original position before riding.
STARTING A WARM ENGINE
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke)
should not be used. The throttle should be
opened slightly.
CAUTION:
See “Engine break-in Section” prior to
operating engine for the first time.
WARMING UP
To get maximum engine life, always “warm-up”
the engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, see if it responds to throttle
normally with the stater (choke) turned off.
WARNING
Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.
ENGINE BREAK-IN
Brake-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially of
slack cables and drive chain and loose spokes.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.

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 - 2 Oil type or grade:
Engine oil
(For USA and CDN)
At –10 °C (10 °F) or higher È
Yamalube 4 (10W-30) or SAE 10W-30 type
SE/SF/SG motor oil
At 5 °C (40 °F) or higher É
Yamalube 4 (20W-40) or SAE 20W-40 type
SE/SF/SG motor oil
(Except for USA and CDN)
API “SE/SF/SG” or higher grade
Oil capacity:
Engine oil
Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet type element
Fuel:
Type Unleaded gasoline only (USA, AUS and NZ)
Regular unleaded gasoline only
(CDN, Europe and ZA)
Tank capacity 4.2 L (0.92 Imp gal, 1.11 US gal)
Reserve amount 0.5 L (0.11 Imp gal, 0.13 US gal)
Carburetor:
Type VM16SH
Manufacturer MIKUNI
Spark plug:
Type CR6HSA/U20FSR-U
Manufacturer NGK/DENSO
Gap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Clutch type: Wet, multiple-disc and centrifugal automatic
0 10 30 50 70 90 110 130
-20 -10 01020
30 40 50
È
É
˚F
˚C
GENERAL SPECIFICATIONS
1
2

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