oil type YAMAHA TTR90 2006 Owners Manual

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

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

SPEC
2 - 7 Piston:
Piston to cylinder clearance 0.025 ~ 0.045 mm
(0.0010 ~ 0.0018 in)0.15 mm
(0.0059 in)
Piston size “D”46.960 ~ 46.975 mm
(1.8488 ~ 1.8494 in)----
Piston over size (2nd) 47.5 mm (1.8701 in) ----
(4th) 48.0 mm (1.8898 in) ----
Measuring point “H”4 mm (0.16 in) ----
Piston off-set 0.75 mm (0.0295 in) ----
Piston pin bore inside diameter 13.002 ~ 13.013 mm
(0.5119 ~ 0.5123 in)13.045 mm
(0.5136 in)
Piston pin outside diameter 12.996 ~ 13.000 mm
(0.5117 ~ 0.5118 in)12.980 mm
(0.511 in)
Piston rings:
Top ring
Type Barrel ----
Dimensions (B × T) 1.0 × 2.0 mm (0.04 × 0.08 in) ----
End gap (installed) 0.10 ~ 0.25 mm
(0.004 ~ 0.010 in)0.4 mm
(0.016 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring
Type Taper ----
Dimensions (B × T) 1.0 × 2.0 mm (0.04 × 0.08 in) ----
End gap (installed) 0.10 ~ 0.25 mm
(0.004 ~ 0.010 in)0.4 mm
(0.016 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring
Dimensions (B × T) 2.0 × 2.3 mm (0.08 × 0.09 in) ----
End gap (installed) 0.2 ~ 0.7 mm (0.01 ~ 0.03 in) ----Item Standard Limit
H
D
T
B
B
T
B
T
MAINTENANCE SPECIFICATIONS

SPEC
2 - 9 Lubrication system:
Oil filter type Wire mesh type ----
Oil pump type Trochoid type ----
Tip clearance “A” or “B”0.15 mm
(0.0059 in)0.2 mm
(0.0079 in)
Side clearance 0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)0.23 mm
(0.0091 in)
Housing and rotor clearance 0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)0.15 mm
(0.0059 in) Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 11 CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Angular bearing ----
Front suspension:
Front fork travel 110 mm (4.33 in) ----
Fork spring free length 425.1 mm (16.74 in) 417 mm (16.4 in)
Fork spring fitting length 415.1 mm (16.34 in) ----
Spring rate, STD K = 3.4 N/mm
(0.35 kg/mm, 19.41 lb/in)----
Optional spring/spacer No ----
Oil capacity 64 cm
3
(2.26 Imp oz, 2.16 US oz) ----
Oil level 185 mm (7.28 in) ----
Oil grade Fork oil 15W or equivalent ----
Rear suspension:
Shock absorber travel 48 mm (1.89 in) ----
Spring free length 169 mm (6.65 in) ----
Fitting length 165 mm (6.5 in) ----
Spring rate, STD K = 45.6 N/mm
(4.65 kg/mm, 260 lb/in)----
Optional spring No ----
Enclosed gas pressure 2,000 kPa
(20 kg/cm
2, 290 psi)----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)
Side clearance ---- 0.3 mm (0.01 in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 14 × 1.40/steel ----
Rear rim size/material 12 × 1.60/steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID420(I)/DAIDO ----
Number of links 86 links ----
Chain slack 40 ~ 53 mm (1.6 ~ 2.1 in) ----
Chain length (15 links) ---- 194.3 mm
(7.65 in)
MAINTENANCE SPECIFICATIONS

SPEC
2 - 14
EC212300
ELECTRICAL
TT-R90
Item Standard Limit
CDI:
Magneto-model/manufacturer F5HN 00/YAMAHA ----
Source coil resistance (color) 688 ~ 1,032 Ω at 20 °C (68 °F)
(Brown – Green)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(Red – White)----
CDI unit-model/manufacturer 4GL-20/YAMAHA ----
Ignition coil:
Model/manufacturer 2JN-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ----
Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 °C (68 °F) ----
Spark plug cap:
Type Resin ----
Resistance 10 kΩ at 20 °C (68 °F) ----
MAINTENANCE SPECIFICATIONS

SPEC
2 - 15 TT-R90E
Item Standard Limit
CDI:
Magneto-model/manufacturer F5HN/YAMAHA ----
Source coil resistance (color) 688 ~ 1,032 Ω at 20 °C (68 °F)
(Brown – Green)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(Red – White)----
CDI unit-model/manufacturer 5HN/YAMAHA ----
Ignition coil:
Model/manufacturer 2JN-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ----
Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 °C (68 °F) ----
Spark plug cap:
Type Resin ----
Resistance 10 kΩ at 20 °C (68 °F) ----
Charging system:
System type CDI magneto ----
Model/manufacturer F5HN/YAMAHA ----
Normal output 14 V/100 W at 5,000 r/min ----
Lighting coil 1 resistance (color) 0.64 ~ 0.96 Ω at 20 °C (68 °F)
(White – Black)----
Lighting coil 2 resistance (color) 0.52 ~ 0.78 Ω at 20 °C (68 °F)
(Yellow – Black)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacturer SH620B-12/SHINDENGEN ----
No-load regulated voltage 14.0 ~ 15.0 V ----
Rectifier capacity 8 A ----
Electric starting system:
Type Constant mesh
Starter motor:
Model/manufacturer 5HN/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.018 ~ 0.022 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Brush quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)3.92 N
(400g,
14.1 oz)
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in) ----
MAINTENANCE SPECIFICATIONS

2 - 11
SPECCARACTERISTIQUES D’ENTRETIEN
CHASSIS
Elément Standard Limite
Système de direction:
Type de roulement de direction Roulement oblique ----
Suspension avant:
Débattement de fourche 110 mm (4,33 in) ----
Longueur libre de ressort de fourche 425,1 mm (16,74 in) 417 mm (16,4 in)
Longueur de ressort de fourche installé415,1 mm (16,34 in) ----
Raideur de ressort, standard K = 3,4 N/mm
(0,35 kg/mm, 19,41 lb/in)----
Ressort/entretoise en option Non ----
Capacité d’huile 64 cm
3 (2,26 Imp oz, 2,16 US oz) ----
Niveau d’huile 185 mm (7,28 in) ----
Qualité d’huile Huile de fourche 15W ou équivalente ----
Suspension arrière:
Débattement d’amortisseur 48 mm (1,89 in) ----
Longueur de ressort libre 169 mm (6,65 in) ----
Longueur monté165 mm (6,5 in) ----
Raideur de ressort, standard K = 45,6 N/mm
(4,65 kg/mm, 260 lb/in)----
Ressort en option Non ----
Pression du gaz enfermé2.000 kPa
(20 kg/cm
2, 290 psi)----
Bras oscillant:
Limite de jeu du bras oscillant
A l’extrémité---- 1,0 mm (0,04 in)
Jeu latéral ---- 0,3 mm (0,01 in)
Roue:
Type de roue avant Roue à rayons ----
Type de roue arrière Roue à rayons ----
Taille/matériau de la jante avant 14 × 1,40/acier ----
Taille/matériau de la jante arrière 12 × 1,60/acier ----
Limite de voile de la jante:
Radial ---- 2,0 mm (0,08 in)
Latéral ---- 2,0 mm (0,08 in)
Chaîne de transmission:
Type/fabricant DID420(I)/DAIDO ----
Nombre de maillons 86 maillons ----
Flèche de la chaîne 40 à 53 mm (1,6 à 2,1 in) ----
Longueur de la chaîne (15 maillons) ---- 194,3 mm
(7,65 in)