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Yamaha RS90NL, Supplementary Service Manual

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Yamaha RS90NL Supplementary Service Manual Download Page 145

141

SPEC

CABLE ROUTING

1

Pass the A.C. magneto lead and
the wire harness through the cut-
out in the front panel.

2

Front panel

3

To the parking brake

4

Wire harness

5

To the brake caliper

6

Route the starter cable under the
throttle cable, brake hose, and
parking brake cable.

7

Pass the plastic band through
the slots near the center of the
rubber cover, and then fasten the
cover to the brake hose with the
band.

8

Throttle cable

9

To the tail/brake light

0

Starter cable

A

Parking brake cable

B

Brake hose

C

After connecting the thumb
warmer leads, thumb warmer
adjustment switch lead, engine
stop switch lead, throttle switch
leads, grip warmer lead, grip
warmer adjustment switch lead,
brake light switch lead, headlight
beam switch lead, and joint cou-
pler, fold the rubber cover around
the leads, and then pull the pro-
jections on one side of the cover
through the corresponding holes
on the other side to close it.

D

Rubber cover

Summary of Contents for RS90NL

Page 1: ...SUPPLEMENTARY SERVICE MANUAL RS90NL RS90NRL RS90RSL RS90GTL RS90MSL LIT 12618 02 47 8GE 28197 10 PRINTED IN U S A 2005 07 CR E YAMAHA MOTOR CO LTD Cover_SMB fm Page 1 Friday July 22 2005 8 54 AM...

Page 2: ...Manual together with following man ual RS90K RS90RK RSG90K RS90MK RST90K RST90TFK SERVICE MANUAL 8FJ 28197 10 981096 LIT 12618 02 38 RS90NL RS90NRL RS90RSL RS90GTL RS90MSL SUPPLEMENTARY SERVICE MANUAL...

Page 3: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will where applicable appear in future editions of this manual HOW TO USE THIS MANUAL Particular...

Page 4: ...g fluid A Lubricant B Tightening C Wear limit clearance D Engine speed E Special tool F V A Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrica tion...

Page 5: ...ENERAL INFORMATION GEN INFO 1 PERIODIC INSPECTION AND ADJUSTMENT INSP ADJ 2 CHASSIS CHAS 3 POWER TRAIN POWR TR 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETION CARB 7 ELECTRICAL ELEC 8 SPECIFICATIONS...

Page 6: ...TION 49 WITH REVERSE MODEL 50 REMOVAL 53 INSTALLATION 54 SECONDARY SHAFT 56 INSTALLATION 56 SECONDARY SHAFT AND DRIVE CHAIN HOUSING INSTALLATION 58 BRAKE 60 BRAKE CALIPER DISASSEMBLY 63 BRAKE CALIPER...

Page 7: ...ed by the use of improper tools or improvised techniques NOTE Be sure to use the correct part number when ordering the tool since the part number may differ according to country For USA and Canada use...

Page 8: ...s Pre opera tion check Daily Initial 1 month or 800 km 500 mi 40 hr Every Seasonally or 4 000 km 2 500 mi 200 hr Spark plugs Check condition Adjust gap and clean Replace if necessary Valve clearance C...

Page 9: ...sary Slide runners Check for wear and damage Replace if necessary Brake and parking brake Check operation and fluid leakage Adjust free play and or replace pads if necessary Replace brake fluid See NO...

Page 10: ...mn bearing Lubricate with specified grease Ski and front suspension Lubricate with specified grease Suspension component Lubricate with specified grease Parking brake cable end and lever end throttle...

Page 11: ...il the brake lever is in the desired position Tighten the locknut CAUTION Be sure to tighten the locknut as failing to do so will cause poor brake performance a 1 2 b c LUBRICATION Brake lever throttl...

Page 12: ...suspension 1 Use a grease gun to inject grease into the nip ples 1 and 2 Both side 2 Apply grease 3 Front Rear RS90N RS90NR RS90RS Rear RS90GT 1 Nipple Recommended lubricant ESSO Beacon 325 Grease or...

Page 13: ...7 INSP ADJ LUBRICATION 1 1 2 1 Rear RS90MS 1 Nipple...

Page 14: ...uretor synchronization Carburetor tuning data 1 Standard specifications Type CVK40 Manufacturer KEIHIN I D Mark 8ES1 00 Main jet M J 148 Pilot jet P J 45 Float height 16 mm 0 63 in Idle speed 1 300 1...

Page 15: ...condition of the spark plugs it is easy to get some idea of the condition of the engine This may diagnose potential problems before engine damage occurs High altitude tuning Use the chart in CHAPTER 9...

Page 16: ...10 INSP ADJ CARBURETOR TUNING Guide for carburetion...

Page 17: ...arly clean the air filter and keep it free from obstruc tions Low speed tuning The carburetors are built so that low speed tuning can be done by adjusting the throttle stop screw 1 CAUTION Never run t...

Page 18: ...e Return the starter lever to its seated position so that the starter valve is fully closed Fuel passage is clogged or frozen Check and if necessary clean the fuel tank air vent the fuel filter and al...

Page 19: ...k Clean the fuel tank Air leaks into the fuel line Tighten or replace the fuel line joint Low fuel pump performance Repair or replace the fuel pump Clogged fuel filter Replace the fuel filter Clogged...

Page 20: ...L Primary sheave spring 90501 582L2 Color G S G Free length 86 1 mm 3 39 in Preload 343 N 35 kg 77 lb Spring rate 27 0 N mm 2 75 kg mm 154 lb in Wire diameter 5 8 mm 0 228 in Outside diameter 59 5 mm...

Page 21: ...ary sheave spring 90501 582L2 Color G S G Free length 86 1 mm 3 39 in Preload 343 N 35 kg 77 lb Spring rate 27 0 N mm 2 75 kg mm 154 lb in Wire diameter 5 8 mm 0 228 in Outside diameter 59 5 mm 2 34 i...

Page 22: ...G S G O S O Free length 87 4 mm 3 44 in 86 1 mm 3 39 in 84 2 m 3 31 in Preload 343 N 35 kg 77 lb Spring rate 24 5 N mm 2 5 kg mm 140 lb in 27 0 N mm 2 75 kg mm 154 lb in 31 9 Nm 3 25 kg mm 182 lb in...

Page 23: ...ave spring 90501 624L8 Color O S O Free length 84 2 mm 3 31 in Preload 343 N 35 kg 77 lb Spring rate 31 9 Nm 3 25 kg mm 182 lb in Wire diameter 6 2 mm 0 244 in Outside diameter 59 5 mm 2 34 in Weight...

Page 24: ...orable condi tions wet snow icy snow hills or rough terrain however engine speed may decrease after the shifting speed has been reached Engine speed Good condition Clutch shifting speed Clutch engagem...

Page 25: ...8 links 1 54 70 links 38 teeth 1 90 68 links 1 81 68 links 1 73 68 links 1 65 70 links 1 58 70 links 39 teeth 2 17 68 links 2 05 68 links 1 95 68 links 1 86 68 links 1 77 70 links 1 70 70 links 1 63 7...

Page 26: ...2 20 50 80 110 3 30 60 90 120 Effects Part no Cam angle Identification mark Standard Quicker upshifting dur ing acceleration Quicker backshifting under load 8FA 17604 00 51 43 8BVFA 8BV 17604 71 47 8...

Page 27: ...L7 24 5 2 50 392 40 Yellow Green Yellow 5 8 0 228 59 5 2 34 4 92 89 4 3 52 90501 583L0 19 6 2 00 441 45 Blue White Blue 5 8 0 228 59 5 2 34 5 65 95 9 3 78 90501 583L1 22 1 2 25 441 45 White White Whit...

Page 28: ...sh and rivets Shape ID mark Standard 8BU 17605 20 45 41 1 603 RS90MS 8CH 17605 10 35 32 1 247 8DG 17605 00 34 26 1 209 8DJ 17605 00 37 77 1 333 8DN 17605 10 39 76 1 404 8ES 17605 00 54 63 1 928 RS90N...

Page 29: ...0 3 0 406 0 85 0 030 OUT RS90MS 90266 06001 Aluminum 13 3 0 524 0 85 0 030 with hole None IN RS90MS I D 9 mm 0 354 in Roller with bush ing part number Outside diameter mm in Bushing type P N Identific...

Page 30: ...stance Standard Shorter Longer Preload Harder Softer Length a Minimum 220 mm 8 66 in 230 mm 9 06 in Maximum 236 5 mm 9 31 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a...

Page 31: ...urning the adjuster 1 With the adjuster fully turned lightly in direction a CAUTION Do not continue to turn the adjuster in direc tion a after it stops The shock absorber can be damaged and rebound da...

Page 32: ...direction b more than 12 clicks Even if the adjuster is continu ally turned after 12 clicks there will be no change in the compression damping force Be sure to stop the adjuster at a position where th...

Page 33: ...o 4 No 3 No 2 No 1 1 2 Choosing other settings CAUTION The standard settings work well under most general riding conditions The suspension can be adjusted to work better in one condition but only at t...

Page 34: ...s shock absorber contains highly pressur ized nitrogen gas Do not tamper with or attempt to open the shock absorber assembly Do not subject the shock absorber assembly to flames or high heat which cou...

Page 35: ...Spring rate Soft Medium Hard Standard M Spring adjuster position 1 2 3 4 5 6 7 Preload Softer Harder Standard 4 1 Rebound damping force adjustment RS90GT The rebound damping force can be adjusted by...

Page 36: ...orce adjustment RS90N RS90NR RS90RS The compression damping force can be adjusted by turning the adjuster 1 With the adjuster fully turned lightly in direction a CAUTION Do not continue to turn the ad...

Page 37: ...ated on the rods with red paint 3 While holding the adjusting bolt securely tighten the locknut 1 Adjusting position 1 2 3 Effect Increase weight transfer Decrease weight transfer Standard 2 T R Lockn...

Page 38: ...within the range f of the scale While holding the adjuster securely tighten the locknut CAUTION When using the special wrench make sure that it is situated at a right angle to the control rod and that...

Page 39: ...Disconnect 6 Engine stop switch coupler 1 Disconnect 7 Throttle switch coupler 2 Disconnect 8 Grip warmer lead connector 2 Disconnect 9 Grip warmer adjustment switch lead cou pler 1 Disconnect 10 Bra...

Page 40: ...stalling all parts refer to CABLE ROUTING in CHAPTER 9 to check the cable and lead routings 20 Handlebar holder 2 21 Handlebar 1 22 Steering joint 1 23 Steering joint bracket cover 1 24 Steering joint...

Page 41: ...r adjustment switch lead coupler 1 Disconnect 5 Engine stop switch coupler 1 Disconnect 6 Throttle switch coupler 2 Disconnect 7 Grip warmer lead connector 4 Disconnect 8 Brake light switch coupler 1...

Page 42: ...r cylinder assembly 1 NOTE After installing all parts refer to CABLE ROUTING in CHAPTER 9 to check the cable and lead routings 16 Handlebar holder upper 2 17 Cable holder 1 18 Handlebar 1 19 Handlebar...

Page 43: ...7 m kg 48 ft lb 2 Install Idler arm 1 Bushings Washers Relay rod 2 Cotter pins CAUTION Always use new cotter pins NOTE Install the idler arm with the R mark a on the right side facing towards the rea...

Page 44: ...ide Tie rod part number Set length a Tie rod length b 8ES 23830 00 RS90N RS90NR RS90RS RS90GT 424 0 mm 16 69 in 361 0 mm 14 21 in 8FW 23830 00 RS90MS 374 0 mm 14 72 in 311 0 mm 12 24 in Tie rod angle...

Page 45: ...ght angles to the handlebar Install the steering linkage alignment plate 1 Loosen the locknuts steering shaft 2 Hold the handlebar straight Adjust the steering shaft 3 by turning so that the right and...

Page 46: ...ng joint T R Handlebar holder bolt 15 Nm 1 5 m kg 11 ft lb a b 1 2 10 Install RS90GT Handlebar CAUTION Be sure the projection on the handlebar is not installed into the area a shown Be sure the side o...

Page 47: ...0NR RS90RS RS90GT Order Job name Part name Q ty Remarks Ski removal Remove the parts in the order listed below 1 Cotter pin 1 2 Nut 1 3 Bolt 1 4 Collar 1 5 Ski stopper 1 6 Ski 1 For installation rever...

Page 48: ...Order Job name Part name Q ty Remarks Ski removal Remove the parts in the order listed below 1 Cotter pin 1 2 Nut 1 3 Bolt 1 4 Collar 2 5 Collar 1 6 Ski stopper 1 7 Ski 1 For installation reverse the...

Page 49: ...sion removal Remove the parts in the order listed below Ski Refer to SKI 1 Front cover 1 2 Shock absorber 1 3 Collar 1 4 Cap 1 5 Cotter pin 1 6 Tie rod 1 Disconnect 7 Steering arm 1 8 Ski column 1 9 B...

Page 50: ...45 CHAS FRONT SUSPENSION Order Job name Part name Q ty Remarks 15 Stabilizer 1 16 Bushing 1 17 Steering knuckle 1 18 Collar 2 For installation reverse the removal proce dure...

Page 51: ...e parts in the order listed below 1 Primary sheave cap 1 2 Primary sheave spring 1 3 Collar 3 4 Roller 3 5 Washer 6 6 Collar 3 7 Weight 3 8 Washer 6 9 Fixed sheave 1 0 Stopper 2 A Sliding sheave 1 B B...

Page 52: ...er listed below Secondary sheave Refer to SECONDARY SHEAVE Right side cover brake caliper parking brake Refer to BRAKE 1 Shim t 0 5 2 Shim t 1 0 3 Spacer 1 4 Brake disc 1 5 Straight key 1 6 Spacer 1 t...

Page 53: ...HAIN HOUSING Order Job name Part name Q ty Remarks 14 Spacer 1 15 Drive sprocket 1 16 Spacer 1 17 Driven sprocket 1 18 Spacer 1 19 Drive chain 1 20 Drive chain housing 1 For installation reverse the r...

Page 54: ...g sure that there are no gaps Be sure to install the spacers in their original positions otherwise the brake disc and jack shaft will stick 0 2 0 7 mm 0 008 0 028 in ESSO beacon 325 grease or Aeroshel...

Page 55: ...ONDARY SHEAVE Right side cover brake caliper parking brake Refer to BRAKE 1 Shim t 0 5 2 Shim t 1 0 3 Spacer 1 4 Brake disc 1 5 Straight key 1 6 Spacer 1 t 1 0 7 Drain bolt 1 Drain 8 Chain tension adj...

Page 56: ...ng cover 1 16 Rubber seal 1 17 Washer 1 18 Counter gear 1 19 Spring 1 20 Chain tensioner 1 21 Washer 1 t 0 5 22 Spacer 1 23 Spacer 1 24 Spring 1 25 Reverse driven gear 1 26 Journal 1 27 Washer 1 28 Fo...

Page 57: ...52 POWR TR DRIVE CHAIN HOUSING Order Job name Part name Q ty Remarks 33 Drive sprocket 1 34 Spacer 1 35 Plate 1 36 Shaft 1 37 Drive chain housing 1 For installation reverse the removal proce dure...

Page 58: ...model NOTE While holding the front axle assembly with spanner wrench 2 loosen the reverse driven gear bolt 1 2 2 Remove Drive sprocket nut 1 NOTE While holding the secondary shaft with the second ary...

Page 59: ...spacers in their original positions otherwise the brake disc and jack shaft will stick 0 2 0 7 mm 0 008 0 028 in 0 1 0 mm 0 0 04 in ESSO beacon 325 grease or Aeroshell grease 7A For the jackshaft and...

Page 60: ...tion Loosen the locknuts 2 Turn the shift rod 1 so that shift rod free play is 0 mm in direction where a can be shortened appropriately and then turn back the shift rod 1 2 turns Tighten the locknuts...

Page 61: ...l Drive chain housing parts Refer to DRIVE CHAIN HOUSING 3 Tighten Drive sprocket nut 1 NOTE While holding the secondary shaft with the second ary shaft slide holder 2 tighten the drive sprocket nut w...

Page 62: ...ry shaft slide holder only with the inner race of the bearing Secondary shaft slide holder 90890 01492 YS 01492 6 Tighten Bearing collar nut 1 NOTE Install the ring nut wrench 2 and then tighten the b...

Page 63: ...nto the drive chain housing making sure that these are no gaps Tighten the bolt 4 Tighten the bolts 5 Tighten the bolts 6 Install the spacer Tighten the spacer set screw 7 Install the brake disc Adjus...

Page 64: ...t 3 Adjust Brake disc clearance Adjustment steps Remove the circlip 8 Adjust the brake disc clearance by adding or removing shim s 9 Install the new circlip Brake disc clearance 0 2 0 7 mm 0 008 0 028...

Page 65: ...move the parts in the order listed below 1 Right side cover 1 2 Cap bolt 1 3 Retaining pin 1 4 Pad spring 1 5 Brake pad 2 6 Brake caliper assembly 1 For installation reverse the removal proce dure 5 6...

Page 66: ...per and parking brake removal Remove the parts in the order listed below Brake fluid Drain 1 Brake hose 1 2 Brake caliper assembly 1 3 Parking brake cable 1 4 Spring 1 5 Parking brake assembly 1 6 Col...

Page 67: ...in the order listed below 1 Cap bolt 1 2 Retaining pin 1 3 Pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 2 For assembly reverse the disassembly pro c...

Page 68: ...opening a to force out the left piston from the caliper body Remove the piston seals and reinstall the pis ton Repeat the previous steps to force out the right piston from the caliper body WARNING Nev...

Page 69: ...CHAPTER 3 1 Brake switch 1 2 Brake lever 1 3 Union bolt 1 4 Holder 1 5 Parking brake cable 1 Disconnect 6 Parking brake lever 1 7 Master cylinder assembly 1 For installation reverse the removal proce...

Page 70: ...1 Brake switch 1 2 Brake lever 1 3 Union bolt 1 4 Holder 1 5 Parking brake cable 1 Disconnect 6 Parking brake lever 1 7 Master cylinder assembly 1 For installation reverse the removal proce dure Brak...

Page 71: ...ON RS90N RS90NR RS90RS Order Job name Part name Q ty Remarks Slide rail suspension removal Remove the parts in the order listed below Rear axle nut Loosen Tension adjuster Loosen 1 Slide rail suspensi...

Page 72: ...opper band 2 2 Front shock absorber 1 3 Bushing 4 4 Collar 2 5 Front pivot arm 1 6 Bushing 2 7 Shaft 1 8 Collar 2 9 Shaft 1 0 Collar 1 A Collar 2 B Collar 1 C Shaft 1 4 Nm 0 4 m kg 2 9 ft lb 49 Nm 4 9...

Page 73: ...se to the inner surface of each spring end guide G Spring end guide bracket 2 H Wheel bracket 2 I Suspension wheel 2 J Bushing 2 K Shaft 1 L Front suspension bracket 1 M Collar 1 I H J K L M I J H E D...

Page 74: ...eel 2 S Torsion spring 2 T Rear pivot arm 1 U Bushing 2 V Rear pivot arm protector 2 W Shaft 1 X Circlip 2 Y Adjuster 2 25 Nm 2 5 m kg 18 ft lb 9 Nm 0 9 m kg 6 5 ft lb 49 Nm 4 9 m kg 35 ft lb 72 Nm 7...

Page 75: ...od stopper 1 _ Circlip 2 a Control rod 2 b Locknut 2 c Adjuster nut 2 d Bushing 4 25 Nm 2 5 m kg 18 ft lb 9 Nm 0 9 m kg 6 5 ft lb 49 Nm 4 9 m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb 60 Nm 6 0 m kg 43 ft l...

Page 76: ...name Part name Q ty Remarks e Rear axle 1 f Guide wheel 2 g Guide wheel 1 h Collar 2 i Tension adjuster 2 j Collar 1 k Collar 1 l Sliding frame 2 For assembly reverse the disassembly pro cedure 75 Nm...

Page 77: ...Order Job name Part name Q ty Remarks Slide rail suspension removal Remove the parts in the order listed below Rear axle nut Loosen Tension adjuster Loosen 1 Slide rail suspension 1 2 Collar 2 For ins...

Page 78: ...elow 1 Shock absorber adjuster assembly 1 2 Stopper band 1 3 Spacer 2 4 Collar 1 5 Collar 1 6 Front pivot arm 1 7 Shaft 1 8 Suspension wheel 2 9 Suspension wheel bracket 2 0 Front pivot arm bracket 2...

Page 79: ...ock absorber 1 L Collar 1 M Bushing 4 N Bearing 2 O Control rod assembly 1 P Spacer 2 Q Collar 1 R Oil seal 4 S Bearing 2 T Rear pivot arm 1 U Rear pivot arm bracket 1 V Guide wheel 2 W Washer 4 X Bus...

Page 80: ...name Part name Q ty Remarks _ Rear axle shaft 1 a Guide wheel 2 b Guide wheel 1 c Collar 2 d Tension adjuster 2 e Collar 1 f Collar 1 g Sliding frame 1 For assembly reverse the disassembly pro cedure...

Page 81: ...b name Part name Q ty Remarks Slide rail suspension removal Remove the parts in the order listed below Rear axle nut Loosen Tension adjuster Loosen 1 Slide rail suspension 1 For installation reverse t...

Page 82: ...topper band 2 2 Front shock absorber 1 3 Bushing 4 4 Collar 2 5 Front pivot arm 1 6 Bushing 2 7 Shaft 1 8 Collar 2 9 Shaft 1 0 Collar 1 A Collar 2 B Collar 1 C Shaft 1 4 Nm 0 4 m kg 2 9 ft lb 49 Nm 4...

Page 83: ...nner surface of each spring end guide G Spring end guide bracket 2 H Wheel bracket 2 I Suspension wheel 2 J Bushing 2 K Shaft 1 L Front suspension bracket 1 M Connecting arm 1 N Collar 1 I H J K L N I...

Page 84: ...ollar 2 Y Guide wheel 2 Z Torsion spring 2 Suspension wheel 2 Wheel bracket 2 Rear pivot arm 1 _ Bushing 2 a Rear pivot arm protector 2 b Shaft 1 9 Nm 0 9 m kg 6 5 ft lb 25 Nm 2 5 m kg 18 ft lb 49 Nm...

Page 85: ...d stopper 1 i Circlip 2 j Control rod 2 k Locknut 2 l Adjuster nut 2 m Bushing 4 9 Nm 0 9 m kg 6 5 ft lb 25 Nm 2 5 m kg 18 ft lb 49 Nm 4 9 m kg 35 ft lb 72 Nm 7 2 m kg 52 ft lb 60 Nm 6 0 m kg 43 ft lb...

Page 86: ...ty Remarks n Shaft 1 o Rear axle 1 p Guide wheel 2 q Guide wheel 1 r Collar 2 s Tension adjuster 2 t Collar 1 u Collar 1 v Sliding frame 2 For assembly reverse the disassembly pro cedure 75 Nm 7 5 m k...

Page 87: ...bsorber 1 RS90N RS90NR RS90RS NOTE Install the rear shock absorber with its gas cylinder a facing downward a 1 3 Install Front shock absorber 1 RS90N RS90NR RS90RS NOTE Install the front shock absorbe...

Page 88: ...5 Install Rear shock absorber adjuster assembly 1 Guide 2 RS90GT NOTE Install the guide after installing the rear shock absorber adjuster assembly 2 1 INSTALLATION 1 Adjust Track tension Refer to TRAC...

Page 89: ...28 8 9 01 198 7 7 82 2 5P 2 5 0 098P 2 0 197 RS90MS 236 3 9 30 200 7 7 90 Control rod 1 part numbers Control rod stopper part numbers Washer part numbers Washer thickness mm in Upper Q ty Lower Q ty 8...

Page 90: ...Control rod 1 Length a mm in Length b mm in Length c mm in RS90GT 277 3 10 92 150 5 5 93 Control rod 1 parts number Control rod 2 parts number Washer plate parts number Washer plate thickness mm in U...

Page 91: ...arts in the order listed below Drive chain housing Refer to DRIVE CHAIN HOUSING Slide rail suspension Refer to SLIDE RAIL SUSPENSION Secondary sheave Refer to SECONDARY SHEAVE 1 Speed sensor 1 2 Beari...

Page 92: ...S90NR RS90RS RS90GT RS90MS 90 3 mm 3 56 in 140 6 mm 5 54 in 155 4 mm 6 12 in 205 6 mm 8 09 in 105 4 mm 4 15 in 29 6 mm 1 17 in 29 6 mm 1 17 in 27 mm 1 06 in 2 Place the track in the chassis NOTE For t...

Page 93: ...STEERING in CHAPTER 3 1 Rear cover 1 2 Muffler protector 2 3 Tail brake light cover 1 4 Tail brake light sub wire harness 1 Disconnect 5 Seat 1 6 Muffler side cover 2 7 Side cover 2 8 Fuel tank cover...

Page 94: ...er 1 3 Tail brake light cover 1 4 Tail brake light sub wire harness coupler 2 Disconnect 5 Seat 1 6 Muffler side cover 2 7 Side cover 2 8 Fuel tank cover 1 9 Fuel sender coupler 1 Disconnect 10 Fuel h...

Page 95: ...SPENSION in CHAPTER 4 Front axle assembly track Refer to FRONT AXLE AND TRACK in CHAPTER 4 Seat and fuel tank Refer to SEAT AND FUEL TANK 1 Muffler cover 1 2 Muffler 1 3 Muffler band 1 4 Gasket 1 5 Ex...

Page 96: ...low NOTE The following procedure applies to all of the carburetors 1 Throttle stop screw 1 2 Throttle cable holder 1 3 Starter plunger 1 4 Vacuum chamber cover 1 5 Piston valve spring 1 6 Piston valve...

Page 97: ...b name Part name Q ty Remarks A Float chamber 1 B Float pin 1 C Float 1 D Needle valve 1 E Main jet 1 F Needle jet holder 1 G Needle jet 1 H Pilot jet 1 For assembly reverse the disassembly pro cedure...

Page 98: ...ft RS90MS Counterclockwise 3 7 m 12 14 ft RS90N RS90NR RS90RS 3 8 m 12 47 ft RS90GT 4 1 m 13 45 ft RS90MS Engine Engine type Liquid cooled 4 stroke DOHC Cylinder type Backward inclined parallel 3 cyl...

Page 99: ...duction ratio 3 8 1 1 Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio 1 90 40 21 RS90N RS90NR RS90RS 1 73 38 22 RS90GT 2 22 40 18 RS90MS Reverse...

Page 100: ...lb type Halogen bulb Bulb wattage Quantity Headlight 12 V 60 W 55 W 2 Tail Brake light 12 V 5 W 21 W 2 RS90N RS90NR RS90RS RS90GT LED RS90MS Meter light 14 V 50 mA 6 High beam indicator light 14 V 80...

Page 101: ...aft Drive system Chain drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft cap clear anc...

Page 102: ...ust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 4 975 4 990 mm 0 1959 0 1965 in Limit 4 945 mm 0 1947 in Exhaust 4 965 4 980 mm 0 1955 0 1961 in Limit 4 935 mm 0 1943 in Valve guide inside...

Page 103: ...24 482 24 488 mm 0 9639 0 9641 in Limit 24 457 mm 0 9629 in Valve lifter hole inside diameter Intake 24 500 24 518 mm 0 9646 0 9653 in Limit 24 548 mm 0 9665 in Exhaust 24 500 24 518 mm 0 9646 0 9653...

Page 104: ...od Crankshaft pin to big end bearing clearance 0 033 0 050 mm 0 0013 0 0020 in Bearing color code 0 White White 1 Blue Blue 2 Black Black 3 Brown Brown 4 Green Green 5 Yellow Yellow Crank pin Crank pi...

Page 105: ...1 16 8 psi Oil pump Oil pump type Trochoidal Inner rotor to outer rotor tip clearance 0 09 0 15 mm 0 004 0 006 in Outer rotor to oil pump housing clearance 0 03 0 08 mm 0 001 0 003 in Relief valve ope...

Page 106: ...n Primary sheave spring Part number 90501 582L2 RS90N RS90NR RS90RS 90501 582L1 RS90GT 90501 624L8 RS90MS Color code Green Silver Green RS90N RS90NR RS90RS Yellow Silver Yellow RS90GT Orange Silver Or...

Page 107: ...diameter 69 5 mm 2 74 in Wire diameter 6 0 mm 0 24 in Hole position Sheave side spring side twist angle 3 3 60 RS90N RS90NR RS90RS RS90GT 1 6 70 RS90MS Spring rate 12 3 N mm 1 25 kg mm 70 23 lb in 11...

Page 108: ...m 1 18 1 38 in Slide rail suspension rear suspension Front travel 191 0 mm 7 52 in RS90N RS90NR RS90RS 256 0 mm 10 08 in RS90GT 183 0 mm 7 20 in RS90MS Rear travel 292 0 mm 11 50 in RS90N RS90NR RS90R...

Page 109: ...0 3 m s 51 0 kg 0 3 m s 112 4 lb 0 3 m s RS90N RS90NR 660 N 0 3 m s 67 3 kg 0 3 m s 148 4 lb 0 3 m s RS90RS 1 130 N 0 3 m s 115 2 kg 0 3 m s 254 0 lb 0 3 m s RS90GT 460 N 0 3 m s 46 9 kg 0 3 m s 103...

Page 110: ...o center 1 086 mm 42 8 in RS90N RS90NR RS90RS RS90GT 980 mm 38 6 in RS90MS Ski Ski material Plastic Length 1 021 0 mm 40 20 in Width 132 0 mm 5 20 in RS90N RS90NR RS90RS RS90GT 182 0 mm 7 17 in RS90MS...

Page 111: ...S 1 120 N 0 3 m s 114 2 kg 0 3 m s 251 8 lb 0 3 m s RS90GT 930 N 0 3 m s 94 8 kg 0 3 m s 209 1 lb 0 3 m s RS90MS Compression 480 N 0 3 m s 48 9 kg 0 3 m s 107 9 lb 0 3 m s RS90N RS90NR RS90RS 885 N 0...

Page 112: ...ite Ignitor unit model Manufacturer J4T16171 MITSUBISHI Rectifier regulator Type Short circuit type Model Manufacturer FH001 SHINDENGEN No load regulated voltage DC 14 1 14 9 V Capacity DC 35 A Withst...

Page 113: ...1 83 2 24 at 20 C 68 F RS90N RS90NR RS90RS RS90MS 1 53 1 87 at 20 C 68 F RS90GT Thumb warmer Heater resistance 37 0 45 2 at 20 C 68 F Circuit breaker Type Fuse Amperage for individual circuit Main fu...

Page 114: ...14 F 10 C 50 F Altitude Idling speed r min 0 200 m 0 700 ft MJ PJ 150 50 MJ PJ 148 48 MJ PJ 148 45 1 400 200 1 500 m 700 5 000 ft MJ PJ 148 48 MJ PJ 148 45 MJ PJ 145 45 1 400 1 500 3 000 m 5 000 10 0...

Page 115: ...d bolt cooling system 13 1 3 9 4 RS90N RS90NR RS90RS RS90GT Bleed screw cooling system 4 0 4 2 9 RS90MS Oil cooler 10 1 0 7 2 Apply LOCTITE Engine mounting bolt spacer 9 0 9 6 5 Engine mounting nut 65...

Page 116: ...il Crankcase M6 1 0 12 1 2 8 7 Apply the engine oil Primary sheave drive shaft assembly bolt 12 1 2 8 7 Connecting rod and cap See NOTE 3 Balancer 35 3 5 25 Balancer shaft bearing retainer 10 1 0 7 2...

Page 117: ...ly 23 2 3 17 With reverse model Shift lever assembly and lever rod 10 1 0 7 2 With reverse model Lever and drive chain housing cover 10 1 0 7 2 With reverse model Apply LOCTITE Lever rod and lever 10...

Page 118: ...and connecting arm 72 7 2 52 RS90N RS90NR RS90RS RS90MS Front pivot arm and control rod 74 7 4 53 RS90GT Front pivot arm and front pivot arm bracket 72 7 2 52 RS90GT Front pivot arm bracket and slidin...

Page 119: ...e bolt to a torque of 60 Nm 6 0 m kg 43 ft lb Control rod shaft and sliding frame 72 7 2 52 RS90N RS90NR RS90RS RS90MS Rear pivot arm bracket and sliding frame 72 7 2 52 RS90GT Apply LOCTITE Rear axle...

Page 120: ...ring column 1 and relay rod 35 3 5 25 Relay rod and relay arm 30 3 0 22 Relay arm and idler arm 35 3 5 25 Idler arm and tie rod 30 3 0 22 Tie rod and steering arm 35 3 5 25 Idler arm 67 6 7 48 Tie rod...

Page 121: ...ry threads Components should be at room temperature A Distance across flats B Outside thread diameter DEFINITION OF UNITS A nut B bolt General torque specifications Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3...

Page 122: ...118 SPEC CABLE ROUTING G 1 2 3 4 5 6 7 8 9 0 A B C D E F L J H I K M N O U i P Y Z a d h g f c X W V Q R S T U j k l m n b C D D D D C B o p q B A s r A e...

Page 123: ...l level gauge dipstick C Carburetor heater coupler D Fasten the starter motor lead and oil cooler outlet hose with the plastic band Face the end of the plastic band towards the battery bracket E To th...

Page 124: ...120 SPEC CABLE ROUTING G 1 2 3 4 5 6 7 8 9 0 A B C D E F L J H I K M N O U i P Y Z a d h g f c X W V Q R S T U j k l m n b C D D D D C B o p q B A s r A e...

Page 125: ...ten the ignition coil lead under the fuel hoses with the plastic band Fasten the fuel hoses with the holders a Slide the boot completely over the throttle position sensor cou pler and then fasten the...

Page 126: ...122 SPEC CABLE ROUTING G 1 2 3 4 5 6 7 8 9 0 A B C D E F L J H I K M N O U i P Y Z a d h g f c X W V Q R S T U j k l m n b C D D D D C B o p q B A s r A e...

Page 127: ...Headlight relay k Carburetor heater relay l Back buzzer with reverse mod els m Nut n Bolt o Install the starter motor lead ter minal so that the terminal is bent upward p Up q Front r Pickup coil coup...

Page 128: ...124 SPEC CABLE ROUTING 1 7 2 3 4 6 5 A A A A...

Page 129: ...he headlight sub wire harness with the holder 4 Fasten the headlight sub wire harness with the clamp 5 Fasten the headlight sub wire harness at the positioning tape with the plastic band 6 After conne...

Page 130: ...126 SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 A C D E F G H M O N P Y Q R S T X W V U I J K L A A A A B...

Page 131: ...the guide 8 Fasten the fuel sender lead and speed sensor lead with the plas tic band 9 Fasten the brake light switch lead headlight beam switch lead grip warmer adjustment switch lead and grip warmer...

Page 132: ...128 SPEC 1 2 3 4 5 6 7 8 9 0 A C D E F G H M O N P Y Q R S T X W V U I J K L A A A A B CABLE ROUTING...

Page 133: ...e S To the brake caliper T Brake hose U Fasten the wire harness with the plastic band The buckle and the end of the plastic band should not be between the wire harness and the shroud V Fasten the wire...

Page 134: ...130 SPEC CABLE ROUTING 3 J K I H G F E D C B A 0 9 8 7 4 5 6 2 1...

Page 135: ...0 Connect the gear position switch lead to the gear position switch with reverse models or fold the lead back without reverse mod els A Wire harness B Fuse box C Coolant reservoir D Coolant reservoir...

Page 136: ...132 SPEC CABLE ROUTING A B B 1 2 3 4 5 6 7 8 9 0 A B 9 C 0 D E G F B B A...

Page 137: ...d with the holder Secure the frame cross member and the holder to the frame with the nut and bolt 6 Speed sensor lead holder 7 Rivet qty 4 8 Align the punch mark on the bearing holder with the rivet 9...

Page 138: ...134 SPEC CABLE ROUTING 1 5 2 3 4 A B 6 5 7 8 9 0 A C A A B B B A A B...

Page 139: ...otor 2 Starter motor lead 3 Negative battery lead 4 Positive battery lead 5 Ignitor unit 6 Ignitor unit bracket 7 Air filter case latch 8 Battery band 9 Battery cover 0 To the carburetor A Wire harnes...

Page 140: ...136 SPEC CABLE ROUTING A A 7 1 2 3 4 6 5...

Page 141: ...ward 2 Wire harness 3 Battery bracket 4 To the air filter case 5 A C magneto lead 6 Route the crankcase breather hose between the wire harness and the A C magneto lead and then under the battery brack...

Page 142: ...138 SPEC CABLE ROUTING 6 7 8 1 2 3 4 5 9 0...

Page 143: ...throttle cable right handlebar switch leads left handlebar switch leads brake hose and parking brake cable 5 Pass the brake hose parking brake cable and throttle cable through the guide 6 Wire harnes...

Page 144: ...140 SPEC CABLE ROUTING 3 1 2 5 9 7 8 4 D C B A 0 6...

Page 145: ...asten the cover to the brake hose with the band 8 Throttle cable 9 To the tail brake light 0 Starter cable A Parking brake cable B Brake hose C After connecting the thumb warmer leads thumb warmer adj...

Page 146: ...142 SPEC CABLE ROUTING 1...

Page 147: ...143 SPEC CABLE ROUTING RS90N RS90NR RS90RS 1 Position the tail brake light switch lead coupler so that it is not pinched between the seat and tail brake light bracket...

Page 148: ...144 SPEC CABLE ROUTING 1...

Page 149: ...145 SPEC CABLE ROUTING RS90GT 1 Position the tail brake light switch lead coupler so that it is not pinched between the seat and tail brake light bracket...

Page 150: ...146 SPEC CABLE ROUTING 1 2 3 4 5 7 3 6 A A A A...

Page 151: ...ght lead coupler 2 Fasten the sub tail brake light lead with the holder 3 Sub tail brake light lead 4 Pass the tail brake light sub wire harness through the cutout in the tail brake light cover 5 Tail...

Page 152: ...L R B B Y B Y B B L Y L Y A G B G B A A B W W Y G B Y G O B L O B L L W L L R R R W R R Y Lg W Lg B Ch BLACK Lg L Lg W B L BLACK Y W Y L Ch Y L Y W B L Y L B BLACK L W Y B L BLACK B W DARK GREEN L G R...

Page 153: ...ture indicator light Y Multi function meter Z Meter light High beam indicator light Auxiliary DC jack fuse Headlight fuse _ Signal fuse a Carburetor heater fuse b Ignition fuse c Auxiliary DC jack 2 d...

Page 154: ...W W Y G B Y G O B L O B L L W L L R R R W R R Y Lg W Lg L Ch BLACK Lg L Lg W B L BLACK Y W Y L Ch Y L Y W B L Y L B BLACK L W Y B L BLACK B W DARK GREEN L G R W Br W R Y Br R Br R W Br W L R G B B L R...

Page 155: ...temperature indicator light Y Multi function meter Z Meter light High beam indicator light Auxiliary DC jack fuse Headlight fuse _ Signal fuse a Carburetor heater fuse b Ignition fuse c Auxiliary DC...

Page 156: ...SUPPLEMENTARY SERVICE MANUAL RS90NL RS90NRL RS90RSL RS90GTL RS90MSL LIT 12618 02 47 8GE 28197 10 PRINTED IN U S A 2005 07 CR E YAMAHA MOTOR CO LTD Cover_SMB fm Page 1 Friday July 22 2005 8 54 AM...

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