wheel YAMAHA TTR90 2007 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU23290
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU34221
Battery [TT-R90E(W)]The battery is located behind cowling
A. (See page 6-6.)
This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
WARNING
EWA10760


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
1. Battery coupler
2. Battery
3. Battery band
U3P281E0.book Page 24 Monday, April 17, 2006 11:26 AM

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
U3P281E0.book Page 26 Monday, April 17, 2006 11:26 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6 a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU41810
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the locknut at the brake le-
ver, and then turn the adjusting
bolt fully in direction (a).
2. Loosen the axle nut.3. Lift the front wheel off the ground
according to the procedure on
page 6-26.
4. Remove the axle nut and washer.
5. Pull the wheel axle out, and then
remove the wheel.
1. Locknut
2. Brake lever free play adjusting bolt
1. Axle nut
2. Washer
1. Wheel axle
U3P281E0.book Page 27 Monday, April 17, 2006 11:26 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU41691
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle from the
right-hand side.NOTE:Make sure that the slot in the brake
shoe plate fits over the retainer on thefork leg.
3. Lower the front wheel so that it is
on the ground.
4. Install the washer and axle nut,
and then tighten the axle nut to the
specified torque.5. Adjust the brake lever free play.
(See page 6-17.)
6. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41641
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the cotter pin, the nut and
the bolt.
1. Slot
2. Retainer
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
1. Brake torque rod
2. Cotter pin
3. Brake torque rod bolt and nut
4. Brake shoe plate
U3P281E0.book Page 28 Monday, April 17, 2006 11:26 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6 2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake cam-
shaft lever.
3. Loosen the locknut and the drive
chain slack adjusting nut on both
ends of the swingarm.4. Loosen the axle nut.
5. Lift the rear wheel off the ground
according to the procedure on
page 6-26.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the wheel.
8. Remove the wheel.
EAU41651
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Insert the wheel axle from the
right-hand side.
3. Adjust the drive chain slack. (See
page 6-18.)
4. Lower the rear wheel so that it is
on the ground.
5. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
6. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and nut, and then tighten
the bolt to the specified torque.
7. Insert a new cotter pin.
8. Tighten the axle nut to the speci-
fied torque.
9. Adjust the brake pedal position
and free play. (See page 6-17.)
1. Brake rod
2. Brake pedal free play adjusting nut
3. Brake camshaft lever
4. Wheel axle
1. Axle nut
2. Washer
3. Drive chain slack adjusting nut
4. Locknut
Tightening torques:
Brake torque rod bolt:
26 Nm (2.6 m·kgf, 19 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
U3P281E0.book Page 29 Monday, April 17, 2006 11:26 AM

MOTORCYCLE CARE AND STORAGE
7-1
7
EAU40461
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10770


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound afterwashing.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM

MOTORCYCLE CARE AND STORAGE
7-3
7
EAU40651
Storage [TT-R90(W)]Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.CAUTION:
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
WARNING
EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turningthe engine over.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.NOTE:Make any necessary repairs beforestoring the motorcycle.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM

MOTORCYCLE CARE AND STORAGE
7-4
7
EAU26150
Storage [TT-R90E(W)]Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.CAUTION:
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
WARNING
EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turningthe engine over.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
TT-R90 1525 mm (60.0 in)
(AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(NZL)(PRT)(SWE)(ZAF)
TT-R90 1550 mm (61.0 in) (CAN)
TT-R90E 1525 mm (60.0 in)
(AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(NZL)(PRT)(SWE)(ZAF)
TT-R90E 1550 mm (61.0 in) (CAN)
Overall width:
605 mm (23.8 in)
Overall height:
865 mm (34.1 in)
Seat height:
625 mm (24.6 in)
Wheelbase:
1040 mm (40.9 in)
Ground clearance:
TT-R90 160 mm (6.30 in) (CAN)
TT-R90 172 mm (6.77 in)
(AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(NZL)(PRT)(SWE)(ZAF)
TT-R90E 160 mm (6.30 in) (CAN)
TT-R90E 172 mm (6.77 in)
(AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(NZL)(PRT)(SWE)(ZAF)
Minimum turning radius:
1300 mm (51.2 in)
Weight:With oil and fuel:
TT-R90 64.0 kg (141 lb)
TT-R90E 67.0 kg (148 lb)Engine:Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
89.0 cm³ (5.43 cu.in)
Bore × stroke:
47.0 × 51.8 mm (1.85 × 2.04 in)
Compression ratio:
8.50 :1
Starting system:
TT-R90 Kickstarter
TT-R90E Electric starter and kickstarter
Lubrication system:
Wet sumpEngine oil:Type:
TT-R90 SAE10W30 or SAE10W40 or
SAE15W40 or SAE20W40 or SAE20W50
(AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(NZL)(PRT)(SWE)(ZAF)
TT-R90 YAMALUBE 4, SAE10W30 or
SAE20W40 (CAN)
TT-R90E SAE10W30 or SAE10W40 or
SAE15W40 or SAE20W40 or SAE20W50
(AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(NZL)(PRT)(SWE)(ZAF)
TT-R90E YAMALUBE 4, SAE10W30 or
SAE20W40 (CAN)
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Periodic oil change:
0.80 L (0.85 US qt) (0.70 Imp.qt)
Air filter:Air filter element:
Wet element
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
10° 30° 50° 70° 90°
110°
0°
130°F
YAMALUBE 4 (10W30)
or SAE 10W30
YAMALUBE 4 (20W40)
or SAE 20W40
–10° 0° 10° 20° 30°
40° –20°
50°C
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM

SPECIFICATIONS
8-2
8
Fuel:Recommended fuel:
TT-R90 Regular unleaded gasoline only
(AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(PRT)(SWE)(ZAF)
TT-R90 Unleaded gasoline only
(AUS)(NZL)
TT-R90E Regular unleaded gasoline only
(AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP
)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)
(PRT)(SWE)(ZAF)
TT-R90E Unleaded gasoline only
(AUS)(NZL)
Fuel tank capacity:
4.2 L (1.11 US gal) (0.92 Imp.gal)
Fuel reserve amount:
0.5 L (0.13 US gal) (0.11 Imp.gal)Carburetor:Manufacturer:
MIKUNI
Type × quantity:
VM16SH x 1Spark plug (s):Manufacturer/model:
NGK/CR6HSA
Manufacturer/model:
DENSO/U20FSR-U
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-disc and centrifugal
automatic
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 (2.20 in)Front tire:Type:
With tube
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBYTire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
Front wheel:Wheel type:
Spoke wheel
Rim size:
14x1.40Rear wheel:Wheel type:
Spoke wheel
Rim size:
12x1.60Front brake:Type:
Drum brake
Operation:
Right hand operationRear brake:Type:
Drum brake
Operation:
Right foot operation
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM