check engine YAMAHA TTR90 2007 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU40000
NOTE:The air filter needs more frequent service if you are riding in unusually wet or dusty areas.10*Chassis fastenersCheck all chassis fitting and fasteners.
Correct if necessary.√√√
11 Brake lever pivot shaftApply lithium-soap-based grease (all-purpose grease)
lightly.√√
12 Brake pedal pivot shaftApply lithium-soap-based grease (all-purpose grease)
lightly.√√
13 Sidestand pivotCheck operation.
Apply lithium-soap-based grease (all-purpose grease)
lightly.√√
14*Spark arresterClean.√
15*Front forkCheck operation and for grease leakage.
Replace if necessary.√√
16*Shock absorber assem-
blyCheck operation and for oil leakage.
Replace if necessary.√
17*Control cablesApply Yamaha chain and cable lube or engine oil 10W-30
thoroughly.√√√
18*Throttle grip housing and
cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√ No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU19603
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer checkthe vehicle.2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
NGK/CR6HSA
DENSO/U20FSR-U
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
62. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAU39840
Engine oil The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.NOTE:Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result ina false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between theminimum and maximum level marks.
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6 To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
4. Install the engine oil drain bolt, and
then tighten it to the specified
torque.5. Add the specified amount of the
recommended engine oil, and then
install and tighten the engine oil fill-
er cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
6. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.7. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Engine oil drain boltTightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil change quantity:
0.80 L (0.85 US qt) (0.70 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
CAUTION:
ECA15571


Make sure that the mesh and the
sponge material are properly
seated in the air filter case.


The engine should never be op-
erated without the mesh and the
sponge material installed, oth-
erwise the piston(s) and/or cyl-
inder(s) may becomeexcessively worn.
8. Install the air filter case cover by in-
stalling the screws.
NOTE:Make sure that the spark plug cable isrouted as shown.9. Install the panel.
To clean the air filter check hose
1. Check the hoses at the bottom of
the air filter case for accumulated
dirt or water.2. If dirt or water is visible, remove
the hoses, clean them, and then
reinstall them.1. Spark plug cable
1. Air filter check hose
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU39930
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.CAUTION:
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-mance of or damage to the engine.
EAU21360
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.NOTE:
A diagnostic tachometer is needed tomake this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1000–2000
r/min while occasionally revving it
to 4000–5000 r/min.NOTE:The engine is warm when it quickly re-sponds to the throttle.
3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
NOTE:
If the specified idling speed cannot be
obtained as described above, have aYamaha dealer make the adjustment.1. Throttle stop screw
Engine idling speed:
1400–1600 r/min
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EAU21370
Adjusting the throttle cable
free play The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.NOTE:The engine idling speed must be cor-
rectly adjusted before checking and ad-justing the throttle cable free play.
1. Loosen the locknut.2. To increase the throttle cable free
play, turn the adjusting nut in direc-
tion (a). To decrease the throttle
cable free play, turn the adjusting
nut in direction (b).
3. Tighten the locknut.
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle cable free play adjusting nut
2. Locknut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU23090
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10710
Damage to the outer housing of ca-
bles may result in internal rusting
and cause interference with cable
movement. Replace damaged ca-
bles as soon as possible to preventunsafe conditions.
EAU23111
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU23490
Replacing the fuse
[TT-R90E(W)]The fuse box is located under the seat.
(See page 3-7.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
3. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
1. Fuse
2. Spare fuseSpecified fuse:
TT-R90E 10.0 A
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