brake YAMAHA TTR90 2007 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch [TT-R90E(W)] ..............3-1
Handlebar switches ........................3-1
Shift pedal .......................................3-2
Brake lever .....................................3-2
Brake pedal ....................................3-2
Fuel tank cap ..................................3-3
Fuel .................................................3-3
Fuel tank breather hose ..................3-4
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Kickstarter .......................................3-6
Seat ................................................3-7
Sidestand ........................................3-7
Starting circuit cut-off system
[TT-R90E(W)] ...............................3-8
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a
cold engine [TT-R90(W)] ............. 5-1
Starting and warming up a
cold engine [TT-R90E(W)] ........... 5-2
Starting a warm engine .................. 5-2
Shifting ........................................... 5-3
Engine break-in .............................. 5-4
Parking [TT-R90(W)] ....................... 5-4
Parking [TT-R90E(W)]..................... 5-5
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for
the emission control system ....... 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing the
cowling and panel ....................... 6-6
Checking the spark plug ................. 6-7
Engine oil ....................................... 6-8
Cleaning the air filter element ...... 6-10
Cleaning the spark arrester .......... 6-12
Adjusting the carburetor ............... 6-13
Adjusting the engine idling
speed ........................................ 6-13
Adjusting the throttle cable
free play .................................... 6-14Valve clearance ........................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-16
Accessories and replacement
parts ......................................... 6-16
Adjusting the brake lever
free play .................................... 6-17
Adjusting the brake pedal
free play .................................... 6-17
Checking the front and rear
brake shoes .............................. 6-18
Drive chain slack .......................... 6-18
Cleaning and lubricating the
drive chain ................................ 6-20
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-21
Checking and lubricating the
brake and shift pedals .............. 6-21
Checking and lubricating the
brake lever ................................ 6-22
Checking and lubricating the
sidestand .................................. 6-22
Lubricating the swingarm
pivots ........................................ 6-22
Checking the front fork ................. 6-23
Checking the steering .................. 6-23
Checking the wheel bearings ....... 6-24
Battery [TT-R90E(W)] ................... 6-24U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM

DESCRIPTION
2-2
2
EAU10420
Right view1. Spark arrester (page 6-12)
2. Seat (page 3-7)
3. Kickstarter (page 3-6)
4. Fuse [TT-R90E(W)] (page 6-26)
5. Fuel tank (page 3-3)
6. Air filter element (page 6-10)
7. Spark plug cap (page 6-7)
8. Brake pedal (page 3-2)9. Engine oil filler cap (page 6-8)U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments1. Left handlebar switch (page 3-1)
2. Brake lever (page 3-2)
3. Throttle grip (page 6-14)
4. Right handlebar switch [TT-R90E(W)] (page 3-1)
5. Fuel tank cap (page 3-3)
6. Main switch [TT-R90E(W)] (page 3-1)
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU39850
Shift pedal This motorcycle is equipped with a con-
stant-mesh 3-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom po-
sition.
EAU12890
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1. Brake lever
1. Brake pedal
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-9
3
With the engine turned off:
1. Make sure that the engine stop switch is set to “
”.
2. Turn the key to “ON”.
3. Shift the transmission into gear.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
6. Shift the transmission into the neutral position.
7. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES
NOTE:
a warmed-up engine.
NO
The system is OK. The motorcycle can be ridden.
YES
NO
This check is most reliable if performed with
U3P281E0.book Page 9 Monday, April 17, 2006 11:26 AM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-3
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brakeCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-17, 6-18
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-17, 6-18
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-14, 6-21
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-21
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-18, 6-20
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-15, 6-16
Shift pedalMake sure that operation is smooth.
Correct if necessary.6-21
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM

PRE-OPERATION CHECKS
4-3
4
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-21
Brake leverMake sure that operation is smooth.
Lubricate lever pivoting point if necessary.6-22
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-22
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Engine stop switchCheck operation.3-1 ITEM CHECKS PAGE
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU39901
Shifting This motorcycle has a 3-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel.
CAUTION:
ECA15441


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always release the throttle grip
before changing gears to avoid
damaging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt-tle grip is open.
EAU39910
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal.
CAUTION:
ECA15460
Always close the throttle before
shifting gears, otherwise damage to
the engine and drive train may re-sult.
3. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release
the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when
shifting to the next higher gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
1. Shift pedal
2. Neutral positionU3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU35346
General maintenance and lubrication chart 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
1*ClutchCheck operation.
Adjust if necessary.√√√
2*Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes if
necessary.√√√
3*Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes if
necessary.√√√
4*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√
5*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√
6*Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√√
7*Swingarm pivot bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
8 Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly.Every ride
9*Steering bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM

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
U3P281E0.book Page 5 Monday, April 17, 2006 11:26 AM