Yamaha TT-R90(S) Owner'S Service Manual Download Page 280

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ENG

SHIFT FORK, SHIFT CAM AND TRANSMISSION

Extent of removal:

Shift fork, shift cam, main axle and drive axle removal

Main axle disassembly

Drive axle disassembly

Extent of removal

Order

Part name

Q’ty

Remarks

SHIFT FORK, SHIFT CAM
TRANSMISSION REMOVAL

Preparation for removal

Engine assembly

Separate the crankcase.

Refer to “CRANKCASE AND CRANK-
SHAFT” section.

Guide bar

Shift cam

Refer to “REMOVAL POINTS”.

Shift fork 2 “R”

Shift fork 1 “L”

Drive axle assembly

Main axle assembly

2nd pinion gear

Circlip

Washer

Summary of Contents for TT-R90(S)

Page 1: ...5HN 28199 84 TT R90 S TT R90E S OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH...

Page 2: ...S OWNER S SERVICE MANUAL 2003 by Yamaha Motor Co Ltd 1st Edition March 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly pr...

Page 3: ...g auch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R90 S TT R90E S MANUEL D ATELIER DU PROPRIETAIRE 2003 Yamaha Motor Co Ltd 1re dition...

Page 4: ...er NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING READ THIS MANUAL CAREFULLY FOR INSTRUC...

Page 5: ...ite 3 2 Dieses Fahrzeug ist nur f r eine Person zugelassen Zweipersonen Betrieb ist nicht zul ssig Dieses Fahrzeug ist ausschlie lich f r den Einsatz abseits ffentlicher Stra en vorgesehen Der Gebrauc...

Page 6: ...while smoking or in the vicinity of an open flame 2 If you should swallow some gasoline or inhale a lot of gasoline vapor or allow some gasoline to get in your eye s see your doctor immediately If an...

Page 7: ...Untergrund abstellen damit es nicht umfallen kann SICHERHEITSINFORMATION REMARQUE IMPORTANTE Ce v hicule est con u uniquement pour une utilisa tion tout terrain par des pilotes tr s jeunes roulant sou...

Page 8: ...k out of the car buretor or fuel tank 5 Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death with...

Page 9: ...en Helm und spezielle Motorradbekleidung Hand schuhe Stiefel Hosen und Jacken tragen 4 Lors du transport de l engin dans un autre v hicule veiller le garder bien droit et ce que le robinet de carburan...

Page 10: ...is a one seater motorbike Don t give any person a ride 4 Let s learn how to ride properly Ask your parents for any question 5 When riding the machine be sure to wear the protective apparel as illustr...

Page 11: ...hutz 4 Motorrad Handschuhe 5 Motorradstiefel 6 Motocross Hose 7 Lang rmeliges Trainingshemd INFORMATION DE SECURITE 1 Ne pas rouler sur la route 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il...

Page 12: ...lone 7 Before riding the machine ask your par ents to check the machine very carefully 8 Don t touch the areas shown or you ll get burnt in the hand 9 Don t touch rotating or moving parts 10 Before st...

Page 13: ...gen den Teile ber hren 10 Vor dem Starten des Motors sicherstellen da sich das Getriebe in der Leerlaufstel lung befindet 6 Ne jamais partir seul moto Toujours partir avec son instructeur 7 Avant de r...

Page 14: ...n to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of six chapters General Informatio...

Page 15: ...le d sir s Arquer le manuel son bord de la mani re indiqu e pour trouver le symbole de devant d sir et passer une page de la description et l article d sir s AVERTISSEMENT ATTENTION BENUTZERHINWEISE K...

Page 16: ...start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A...

Page 17: ...F r Arbeiten f r die weitere Informationen ben tigt werden sind schrittweise Erg n zungen 6 zus tzlich zu dem Explosions diagramm und der Arbeitsanweisungstabelle aufgef hrt FORMAT DU MANUEL Dans ce m...

Page 18: ...Tightening B Specified value Service limit C Engine speed D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagram indicate grade of lubricant and loca tion of lubr...

Page 19: ...mittel LOCTITE J Erneuern SYMBOLES GRAPHIQUES Voir l illustration Les symboles graphiques 1 6 servent rep rer les diff rents chapitres et indiquer leur contenu 1 Renseignements g n raux 2 Caract risti...

Page 20: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL...

Page 21: ...SPEC 2 REGELM SSIGE INSPEKTION UND EINSTELLARBEITEN 3 MOTOR ENG 4 FAHRWERK CHAS 5 ELEKTRISCHE ANLAGE ELEC 6 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES COU...

Page 22: ...ING AND OPERATION 1 13 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITION OF UNITS 2 17 CABLE ROUTING DIAGRAM 2 18 CHAPTER...

Page 23: ...TEN VOR FAHRTBEGINN 3 2 MOTOR 3 3 FAHRWERK 3 11 ELEKTRISCHE ANLAGE 3 20 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS GENERAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MACHINE 1 2 INFORMATIONS IMPORTANTES...

Page 24: ...GNETO AND STARTER CLUTCH TT R90E 4 41 CRANKCASE AND CRANKSHAFT 4 45 SHIFT FORK SHIFT CAM AND TRANSMISSION 4 48 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT FORK 5 6 HANDLEBAR 5 9 STEERING 5...

Page 25: ...R90E 6 15 VERGASERBEHEIZUNGSSYSTEM 6 17 WARTUNGSPLAN 6 21 CHAPITRE 4 MOTEUR CARBURATEUR 4 1 CULASSE 4 8 ARBRE A CAMES ET CULBUTEURS 4 13 SOUPAPES ET RESSORTS DE SOUPAPE 4 16 CYLINDRE ET PISTON 4 21 EM...

Page 26: ...rottle grip 6 Fuel tank cap 7 Kick starter 8 Fuel tank 9 Air cleaner 0 Rear brake pedal A Fuel cock B Starter lever choke C Drive chain D Shift pedal E Front fork NOTE The machine you have purchased m...

Page 27: ...jederzeit vorbehalten Die Abbildung zeigt das TT R90E Modell RENSEIGNEMENTS GENERAUX DESCRIPTION 1 Coupe circuit du moteur 2 Commutateur principal TT R90E 3 Commutateur de d marrage TT R90E 4 Levier d...

Page 28: ...machine KEY IDENTIFICATION NUMBER TT R90E The key identification number 1 is stamped on the key as shown in the following illustra tion This number can be used for ordering a new key EC121001 VEHICLE...

Page 29: ...erden zur Ersatzteil Bestellung ben tigt IDENTIFICATION DE LA MACHINE Il existe deux bonnes raisons de conna tre les num ros de s rie de sa machine 1 A la commande de pi ces de rechange ces num ros pe...

Page 30: ...Use proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have...

Page 31: ...gen Dies ge w hrleistet einen z gigen und korrekten Zusammenbau 5 Alle Teile von offenem Feuer fernhalten INFORMATIONS IMPORTANTES PREPARATION POUR LA DEPOSE ET DEMONTAGE 1 Eliminer soigneusement cras...

Page 32: ...EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or...

Page 33: ...ous recommandons d utiliser des pi ces Yamaha d origine pour tous les remplace ments Utiliser les huiles graisses recomman d es par Yamaha lors des remontages et r glages JOINTS BAGUES D ETANCHEITE ET...

Page 34: ...e etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air bower 3 Connect and disconnect the connector two or three times 4 Pull the lead to check that it will not come off 5 If th...

Page 35: ...g von Kabelb umen stets die Schritte 1 bis 7 durchf hren Zur schnellen Abhilfe kann ein handels bli ches Kontaktspray verwendet werden Die Steckverbinder wie abgebildet mit dem Me ger t pr fen CIRCLIP...

Page 36: ...se 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 specifi...

Page 37: ...0890 01184 Fork seal driver weight This tool is used to installing the oil seal YM 33963 90890 01184 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checkin...

Page 38: ...uller This tool is used to remove the rotor YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC QUICK GS...

Page 39: ...tracteur inertie Ces outils permettent de d poser et de remonter les axes de culbuteur YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Cl pour crou annulaire Cet outil est utilis pour desserrer...

Page 40: ...de montage de joint de fourche Cet outil permet de monter les bagues d tanch it YM 33963 90890 01184 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Ce testeur est n cessaire...

Page 41: ...utilis pour la d pose du volant magn ti que YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond n 1215 Cet agent d tanch it p te est utilis sur les plans de joint du carter et...

Page 42: ...90 01084 90890 01085 Austreib Set Gewicht Kipphebelwellen Ausbauwerkzeug Zum Montieren oder Demontieren der Kipphebelwel len YU 01083 A 90890 01084 90890 01085 YU 1268 90890 01268 Hakenschl ssel Zum L...

Page 43: ...instellen der Ventile YM 8035 90890 01311 YM 33963 90890 01184 Gabeldichtring Treiber Zum Einbau der Gabeldichtringe YM 33963 90890 01184 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndpr fer Zur b...

Page 44: ...Polrad Abzieher Zum Demontieren des Rotors YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Dichtmasse Nr 1215 Zum Abdichten der Kurbelgeh use Pa fl chen ACC QUICK GS KT 90890 85...

Page 45: ...GEN INFO MEMO...

Page 46: ...e throttle system The engine will not start or run when the engine stop switch is turned to TT R90E The engine stop switch 1 is located on the left handlebar Continue pushing the engine stop switch ti...

Page 47: ...r Maschine den Front bremshebel ziehen das Gas herunterdre hen und den 1 Gang einlegen FONCTIONS DES COMMANDES COMMUTATEUR PRINCIPAL TT R90E Les fonctions du commutateur aux diff rentes posi tions son...

Page 48: ...EC155001 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar it accelerates or decelerates the engine For acceleration turn the grip toward you for deceleration turn it away from you...

Page 49: ...ite des Lenkers FUSSBREMSHEBEL Der Fu bremshebel 1 zur Bet tigung der Hin terradbremse befindet sich auf der rechten Fahrzeugseite KICK AVERTISSEMENT Avant de mettre le moteur en marche veiller ce que...

Page 50: ...position FILL THE TANK AT THE FIRST OPPORTUNITY BE SURE TO SET THE LEVER TO ON AFTER REFUELING STARTER LEVER CHOKE When cold the engine requires a richer air fuel mixture for starting A separate star...

Page 51: ...ersch tten BORDWERKZEUG Z ndkerzenschl ssel Der Z ndkerzenschl ssel 1 dient zum Aus bauen und Einbauen der Z ndkerze Schraubenzieher Dieses Werkzeug dient f r vorbeugende War tung und kleine Reparatur...

Page 52: ...flow when the fuel heats up later and expands a Fuel level CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to the engine internal parts such as valves piston ri...

Page 53: ...men Gesamtinhalt 4 2 L 0 92 Imp gal 1 11 US gal Davon Reserve 0 5 L 0 11 Imp gal 0 13 US gal CARBURANT KRAFTSTOFF CARBURANT Utiliser de l essence normale Toujours utiliser de l essence fra che d une b...

Page 54: ...try using the kickstarter 1 Turn the fuel cock to ON 2 Turn the main switch to ON 3 Shift the transmission into neutral 4 Operate the starter choke and com pletely close the throttle grip 5 Start the...

Page 55: ...le robinet de carburant sur ON 2 Mettre le commutateur principal en position de marche ON 3 Mettre au point mort 4 Ouvrir le starter au maximum et couper les gaz compl tement 5 D marrer le moteur en...

Page 56: ...rten l t verwenden Sie den Kickstarter 1 Kraftstoffhahn in Stellung ON drehen 2 Den Hauptschalter auf ON stellen 3 Das Getriebe auf Leerlauf stellen 4 Den Choke aktivieren den Gasdrehgriff ganz schlie...

Page 57: ...GEN INFO MEMO...

Page 58: ...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 Basic weight With oil and full fuel tank TT R90 64 kg 141 lb TT R90E 67 kg 147 7 lb Engine Engine t...

Page 59: ...otal 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 Regular gasoline ZA Tank capacity 4 2 L 0...

Page 60: ...N Type front and rear KNOBBY Tire pressure front and rear 100 kPa 1 00 kgf cm2 14 5 psi Brake Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Right foot...

Page 61: ...und limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 034 21 134 mm 0 8281 0 8320 in 21 000 mm 0 8268 in...

Page 62: ...9 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 5 0 9 mm 0 0197 0 354...

Page 63: ...in 26 9 mm 1 06 in EX 32 45 mm 1 28 in 26 9 mm 1 06 in Set length valve closed IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Compressed pressure installed IN 138 158 N 14 07 16 11 kg 31 02 35 52 lb EX 138 15...

Page 64: ...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 instal...

Page 65: ...d Inner push cam push Push rod bending limit 0 5 mm 0 02 in Automatic centrifugal clutch Clutch in revolution 2 160 2 560 r min Clutch stall revolution 3 300 3 800 r min Shifter Shifter type Cam drum...

Page 66: ...ump 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...

Page 67: ...7 0 7 5 1 Air filter case M6 1 0 2 7 0 7 5 1 Exhaust pipe M6 1 0 2 7 0 7 5 1 Exhaust pipe protector M6 1 0 7 7 0 7 5 1 Silencer M8 1 25 1 24 2 4 17 Silencer protector M5 0 8 2 4 0 4 2 9 Crankcase M6...

Page 68: ...r 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 cm2 290...

Page 69: ...n Front lining thickness 3 mm 0 12 in 2 mm 0 08 in Rear lining thickness 4 mm 0 16 in 2 mm 0 08 in Front shoe spring free length 32 7 mm 1 29 in Rear shoe spring free length 50 5 mm 1 99 in Brake leve...

Page 70: ...20 2 0 14 Handle crown and handlebar holder lower M10 1 25 2 40 4 0 29 Handlebar holder upper TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Front brake cable holder and front fork M6 1 0 2 7...

Page 71: ...n Pickup coil resistance color 248 372 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 re...

Page 72: ...put 14 V 100 W at 5 000 r min Lighting coil 1 resistance color 0 64 0 96 at 20 C 68 F White Black Lighting coil 2 resistance color 0 52 0 78 at 20 C 68 F Yellow Black Rectifier regulator Regulator typ...

Page 73: ...80 A Coil winding resistance 4 2 4 6 at 20 C 68 F Starting circuit cut off relay Model manufacturer ACM33221 MATSUSHITA Coil winding resistance 75 69 92 51 at 20 C 68 F Fuse amperage quantity Main fus...

Page 74: ...A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6...

Page 75: ...Hauteur de la selle 625 mm 24 6 in Empattement 1 040 mm 40 9 in Garde au sol minimale 160 mm 6 3 in Poids net Avec huile et r servoir de carburant rempli TT R90 64 kg 141 lb TT R90E 67 kg 147 7 lb Mo...

Page 76: ...qt 0 85 US qt Quantit totale 1 0 L 0 88 Imp qt 1 06 US qt Filtre air El ment de type humide Carburant Type Essence sans plomb uniquement USA AUS et NZ Essence normale sans plomb uniquement CDN Europe...

Page 77: ...HENG SHIN Type avant et arri re KNOBBY Pression de gonflage du pneu avant et arri re 100 kPa 1 00 kgf cm2 14 5 psi Freins Type de frein avant Frein tambour Commande Main droite Type de frein arri re F...

Page 78: ...imite d ovalisation 0 05 mm 0 0020 in Arbre cames M thode d entra nement Transmission par cha ne c t gauche Dimensions de came Admission A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 03...

Page 79: ...0 7913 in B largeur de face AD 1 19 2 51 mm 0 0469 0 0989 in ECH 1 49 3 07 mm 0 0587 0 1209 in C largeur de si ge AD 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in ECH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm...

Page 80: ...26 9 mm 1 06 in ECH 32 45 mm 1 28 in 26 9 mm 1 06 in Longueur mont soupape ferm e AD 24 2 mm 0 95 in ECH 24 2 mm 0 95 in Pression la compression install AD 138 158 N 14 07 16 11 kg 31 02 35 52 lb ECH...

Page 81: ...96 13 000 mm 0 5117 0 5118 in 12 980 mm 0 511 in Segments Segment de feu Type Cylindrique Dimensions B T 1 0 2 0 mm 0 04 0 08 in Ecartement des becs segment mont 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 0...

Page 82: ...came Limite de d formation de la tige de commande 0 5 mm 0 02 in Embrayage centrifuge automatique Vitesse d engagement de l embrayage 2 160 2 560 tr mn Vitesse de lib ration de l embrayage 3 300 3 80...

Page 83: ...lis m tallique Type de pompe huile Trocho dale Jeu en bout A ou B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Jeu de lubrification entre le logement...

Page 84: ...rburateur M6 1 0 2 7 0 7 5 1 Bo tier de filtre air M6 1 0 2 7 0 7 5 1 Tuyau d chappement M6 1 0 2 7 0 7 5 1 Protection de tuyau d chappement M6 1 0 7 7 0 7 5 1 Silencieux M8 1 25 1 24 2 4 17 Protectio...

Page 85: ...va lente Suspension arri re D battement d amortisseur 48 mm 1 89 in Longueur libre de ressort 169 mm 6 65 in Longueur mont 165 mm 6 5 in Constante standard de ressort K 45 6 N mm 4 65 kg mm 260 lb in...

Page 86: ...mm 4 33 in 111 mm 4 37 in Epaisseur de la garniture frein avant 3 mm 0 12 in 2 mm 0 08 in Epaisseur de la garniture frein arri re 4 mm 0 16 in 2 mm 0 08 in Longueur libre de ressort de m choire de fr...

Page 87: ...r et demi palier de guidon inf rieur M10 1 25 2 40 4 0 29 Demi palier de guidon sup rieur TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Support de c ble de frein avant et fourche avant M6 1 0...

Page 88: ...C 68 F brun vert R sistance de la bobine d excitation couleur 248 372 20 C 68 F rouge blanc Bloc CDI mod le fabricant 4GL 20 YAMAHA Bobine d allumage Mod le fabricant 2JN 00 YAMAHA Longueur minimum d...

Page 89: ...F5HN YAMAHA Sortie normale 14 V 100 W 5 000 tr mn R sistance 1 de la bobine d allumage couleur 0 64 0 96 20 C 68 F blanc noir R sistance 2 de la bobine d allumage couleur 0 52 0 78 20 C 68 F jaune noi...

Page 90: ...p res 180 A R sistance des spirales de la bobine 4 2 4 6 20 C 68 F Relais du coupe circuit de d marrage Mod le fabricant ACM33221 MATSUSHITA R sistance des spirales de la bobine 75 69 92 51 20 C 68 F...

Page 91: ...s Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filetage DEFINITION DES UNITES A crou B vis CARACTERISTIQUES DE COUPLE Nm m kg ft lb 10mm 12mm 14mm...

Page 92: ...in Sitzh he 625 mm 24 6 in Radstand 1 040 mm 40 9 in Bodenfreiheit 160 mm 6 3 in Fahrzeuggewicht Fahrfertig vollgetankt TT R90 64 kg 141 lb TT R90E 67 kg 147 7 lb Motor Bauart luftgek hlter 1 Zyl 4 Ta...

Page 93: ...esamtmenge 1 0 L 0 88 Imp qt 1 06 US qt Luftfilter Na filter Einsatz Kraftstoff Sorte Ausschlie lich bleifreies Benzin USA AUS und NZ Ausschlie lich bleifreies Normalbenzin CDN Europa Normal ZA Tankin...

Page 94: ...Hersteller vorn und hinten CHENG SHIN Typ vorn und hinten KNOBBY Reifenluftdruck vorn und hinten 100 kPa 1 00 kgf cm2 14 5 psi Bremsanlage vorn Bauart Trommelbremse Bet tigung Handbremshebel rechts hi...

Page 95: ...47 05 mm 1 8524 in Max Ovalit t 0 05 mm 0 0020 in Nockenwelle Antrieb Steuerkette links Nockenabmessungen Einla A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 034 21 134 mm 0 8281 0 832...

Page 96: ...lsitzbreite C Einla 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Ausla 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Ventiltellerst rke D Einla 0 5 0 9 mm 0 0197 0 354 in Ausla 0 8 1 2 mm 0 0315 0 0472...

Page 97: ...26 9 mm 1 06 in Ausla 32 45 mm 1 28 in 26 9 mm 1 06 in Einbaul nge Ventil geschlossen Einla 24 2 mm 0 95 in Ausla 24 2 mm 0 95 in Federdruck eingebaut Einla 138 158 N 14 07 16 11 kg 31 02 35 52 lb Aus...

Page 98: ...in 12 980 mm 0 511 in Kolbenringe 1 Kompressionsring Topring Ausf hrung abgerundet Abmessungen B T 1 0 2 0 mm 0 04 0 08 in Sto spiel eingebaut 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Ringnutspiel...

Page 99: ...ckstangen Verzugsgrenze 0 5 mm 0 02 in Automatische Fliehkraftkupplung Kupplung greift bei 2 160 2 560 U min Bei bet tigter Bremse stirbt Motor bei 3 300 3 800 U min Schaltung Schaltmechanismus Schalt...

Page 100: ...geflecht Einsatz lpumpe Rotorpumpe Radialspiel A oder B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Axialspiel 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Rotor Laufspiel 0 06 0 10 mm 0 0024 0 0039 in 0 15...

Page 101: ...filtergeh use M6 1 0 2 7 0 7 5 1 Kr mmer M6 1 0 2 7 0 7 5 1 Kr mmerschutz M6 1 0 7 7 0 7 5 1 Schalld mpfer M8 1 25 1 24 2 4 17 Schalld mpferschutz M5 0 8 2 4 0 4 2 9 Kurbelgeh use M6 1 0 9 10 1 0 7 2...

Page 102: ...t hinten Federweg 48 mm 1 89 in Feder ungespannte L nge 169 mm 6 65 in Einbaul nge 165 mm 6 5 in Standard Federrate K 45 6 N mm 4 65 kg mm 260 lb in Umr stm glichkeiten Keine Gasdruck 2 000 kPa 20 kg...

Page 103: ...in 111 mm 4 37 in Bremsbelagst rke vorn 3 mm 0 12 in 2 mm 0 08 in Bremsbelagst rke hinten 4 mm 0 16 in 2 mm 0 08 in Bremsbacken R ckholfeder vorn ungespannte L nge 32 7 mm 1 29 in Bremsbacken R ckhol...

Page 104: ...chraube M8 1 25 2 20 2 0 14 Obere Gabelbr cke und Lenkerhalterung unten M10 1 25 2 40 4 0 29 Lenkerhalterung oben TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Vorderradbremszug Halter und Te...

Page 105: ...88 1 032 bei 20 C 68 F braun gr n Impulsgeber Widerstand Farbe 248 372 bei 20 C 68 F rot wei CDI Z ndbox Typ Hersteller 4GL 20 YAMAHA Z ndspule Typ Hersteller 2JN 00 YAMAHA Min Z ndfunkenstrecke 6 mm...

Page 106: ...dell Hersteller F5HN YAMAHA Normalausgang 14 V 100 W bei 5 000 U min Lichtspulenwiderstand 1 Farbe 0 64 0 96 bei 20 C 68 F wei schwarz Lichtspulenwiderstand 2 Farbe 0 52 0 78 bei 20 C 68 F gelb schwar...

Page 107: ...ke 180 A Spulenwicklungswiderstand 4 2 4 6 bei 20 C 68 F Starterkreis Unterbrecherrelais Modell Hersteller ACM33221 MATSUSHITA Spulenwicklungswiderstand 75 69 92 51 bei 20 C 68 F Sicherung St rke Anza...

Page 108: ...und trokkene Schraubverbindungen bei Raumtemperatur A Schl sselweite B Gewindedurchmesserer EINHEITEN A Mutter B Schrau be ALLGEMEINE ANZUGSMOMENTE Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6...

Page 109: ...SPEC MEMO...

Page 110: ...cable A Cable holder B Fuel tank breather hose C Brake cable After fastening the starter cable CDI magneto lead wire harness and thermo switch lead cut off any excess from the plastic locking tie end...

Page 111: ...abel mit Kabelbindern befestigen Bremszug durch Kabelf hrungen leiten CHEMINEMENT DES CABLES TT R90 1 Reniflard de carter 2 Faisceau de fils 3 Fil de magn to CDI 4 C ble de starter 5 Fil de chauffage...

Page 112: ...ire harness A Damper B CDI unit lead C CDI unit D Rectifier regulator lead E Rectifier regulator F Crankcase breather hose G Carburetor breather hose H Spark plug lead I Fuel hose J Starter cable K CD...

Page 113: ...Entl ftungsschlauch H Z ndkabel I Kraftstoffschlauch J Chokezug K Lichtmaschinen Kabel L Thermoschalter 1 Guide de c ble 2 C ble de frein 3 C ble des gaz 4 Reniflard de r servoir de carburant 5 Fil d...

Page 114: ...ead and rectifier regulator lead with the plastic clamp Align the tape on the rectifier regulator lead with the plastic clamp After fastening the engine stop switch lead cut off any excess from the pl...

Page 115: ...n Enden vom Plastikschlauchband abschneiden Z ndbox Kabel durch Kabelf hrung leiten Faire passer le reniflard du r servoir de carburant dans le guide de c ble Faire passer le c ble des gaz et le fil d...

Page 116: ...able C Brake cable D Engine stop switch lead E Main switch lead F Start switch lead Pass the spark plug lead through the lead guide Make sure that the starter cable does not contact the engine bracket...

Page 117: ...Seilzugf hrung ver legen Die Startschalterleitung mit den Plastiksperrb n dern befestigen TT R90E 1 Flexible de reniflard de carter 2 Fil de magn to CDI 3 Faisceau de fils 4 Thermocontact 5 Fil de the...

Page 118: ...Fuel hose J Carburetor heater lead K Carburetor breather hose L Carburetor heater coupler M CDI magneto coupler N CDI unit coupler O CDI unit connector P CDI unit lead Q Thermo switch lead R Thermo sw...

Page 119: ...Leitung V Gleichrichter Regulierer W Starterrelaiskabel 1 Bride 2 Fil de bouton d arr t du moteur 3 Fil de coupe circuit du moteur 4 Fil de bouton de d marrage 5 C ble de frein 6 C ble d acc l rateur...

Page 120: ...stic locking tie For fastening pass the plas tic locking tie through the hole in the bracket After fastening the starter motor lead cut off any excess from the plastic locking tie end After fastening...

Page 121: ...n dass die CDI Einheit Leitung nicht den Thermoschalter B gel ber hrt Faire passer le fil du bouton de d marrage le fil du coupe circuit du moteur le fil du bouton d arr t du moteur et le c ble d acc...

Page 122: ...in switch lead and engine stop switch lead at the tape with the plastic locking tie Fasten the battery leads Fasten the wire harness and starting circuit cut off relay lead at the tape for the wire ha...

Page 123: ...stiksperrband durch das Loch im Batte riekasten f hren Attacher le c ble du d marreur le fil du thermocon tact le fil du bloc CDI le fil du coupe circuit du moteur le fil du bouton de d marrage et le...

Page 124: ...oes not contact the spring rear shock absorber Position the wire harness CDI magneto lead thermo switch lead and CDI unit lead as shown A A A C C D B B B B F F F E E D A A B B E E C F F G G D K K Q R...

Page 125: ...Kabelbaum CDI Magnetz nderleitung Thermoschalterleitung und CDI Einheit Leitung positionieren wie in der Abbildung gezeigt Faire passer le fil du relais de d marreur dans le relais de d marreur Mettre...

Page 126: ...ust if necessary Exhaust systems Check for leakage Retighten if necessary Replace gasket if necessary Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine bef...

Page 127: ...rews are properly tightened Tighten if necessary Sidestand Check operation Lubricate and repair if necessary Spark arrester 1 Clean Front fork Check operation and for oil leakage Correct accordingly R...

Page 128: ...r le joint si n cessaire Huile de moteur Contr ler le niveau d huile et l tanch it Corriger si n cessaire Changer Faire chauffer le moteur avant la vidange Embrayage V rifier le fonctionnement R gler...

Page 129: ...ment serr s Resserrer si n cessaire B quille lat rale V rifier le fonctionnement Lubrifier et r parer si n cessaire Pare tincelles 1 Nettoyer Fourche avant Contr ler le fonctionnement et l tanch it Co...

Page 130: ...ufdrehzahl und Starterfunktion pr fen Gegebenenfalls einstellen Auspuffanlage Auf Undichtigkeit pr fen Gegebenenfalls nachziehen Gegebenenfalls Dichtung erneuern Motor l lstand kontrollieren und Fahrz...

Page 131: ...hend korrigieren Nach jeweils 120 Betriebsstunden mit Lithiumfett schmieren Schraubverbindun gen am Fahrwerk Alle Schrauben und Muttern auf festen Sitz pr fen Gegebenenfalls festziehen Seitenst nder F...

Page 132: ...gine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage Throttle grip free play adjustment steps NOTE Before adj...

Page 133: ...ES CABLES D ACCELERATION NETTOYAGE DU FILTRE A AIR MOTOR GASZUGSPIEL EINSTELLEN LUFTFILTER REINIGEN MOTEUR REGLAGE DES CABLES D ACCELERATION 1 V rifier Jeu la poign e des gaz a Hors sp cification R gl...

Page 134: ...n squeezing the element Leaving too much of solvent in the ele ment may result in poor starting 4 Inspect Air filter element Damage Replace 5 Apply Foam air filter oil or engine mixing oil To the elem...

Page 135: ...uf die Boh rung b am Luftfiltereinsatz ausrichten 7 Montieren Luftfilter Geh usedeckel 8 Montieren Lufthutze rechts 1 Installer Car nage de prise d air droit 1 2 Installer Couvercle du bo tier du filt...

Page 136: ...to proper level NOTE When inspecting the oil level do not screw the dipstick into the oil tank Insert the gauge lightly For USA and CDN CAUTION Do not add any chemical additives Engine oil also lubric...

Page 137: ...ene lsorte Bei 10 C 10 F oder h her Yamalube 4 10W 30 oder SAE 10W 30 SE SF Motor l Bei 5 C 40 F oder h her Yamalube 4 20W 40 oder SAE 20W 40 SE SF Motor CONTR LE DU NIVEAU D HUILE DE MOTEUR 1 Mettre...

Page 138: ...ce again NOTE Wait a few minutes until the oil settles before inspecting the oil level ENGINE OIL REPLACEMENT 1 Start the engine and warm it up for sev eral minutes and wait for five minutes 2 Place t...

Page 139: ...ren geeig net ist Empfohlene Motor l Spezifika tion API NORM API SE SF odr besser vorzugsweise Motorrad l Except les USA et le CDN ATTENTION Ne pas ajouter d additifs chimiques et ne pas uti liser d h...

Page 140: ...oil change 0 8 L 0 70 Imp qt 0 85 US qt 7 Install Dipstick 8 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPEC TION PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjusti...

Page 141: ...bis zum Anschlag eindrehen Leerlaufgemisch Regulierschraube um die angegebene Anzahl von Umdrehungen wieder herausdrehen Leerlaufgemisch Regulier schraube 1 3 4 Umdrehungen heraus 5 Installer Joint B...

Page 142: ...heck or adjust the valve clearance 1 Remove Air scoop right 1 Air filter case 2 2 Remove Spark plug Tappet cover intake side 1 Tappet cover exhaust side 2 Adjustment steps Adjust the pilot screw Refer...

Page 143: ...hraube 1 nach b dre hen um die Leerlaufdrehzahl zu reduzieren Induktivdrehzahlmesser YU 8036 B 90890 03113 Leerlaufdrehzahl 1 400 1 600 U min REGLAGE DU REGIME DE RALENTI 1 Mettre le moteur en marche...

Page 144: ...C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance Adjustment steps Loosen the locknut 1 Turn the adjuster 3 in or out with the valve adju...

Page 145: ...Falls unvorschriftsmig die obige Schritte wiederholen bis das vorgeschriebene Spiel eingestellt ist T R 7 Nm 0 7 m kg 5 1 ft lb 4 Contr ler Jeu de soupapes Hors sp cifications R gler 5 R gler Jeu de s...

Page 146: ...not start the engine when cleaning the exhaust system 1 Remove Bolt tailpipe 1 2 Remove Tailpipe 2 Pull the tailpipe out of the muffler 3 Clean Spark arrester Use a wire brush to remove any carbon dep...

Page 147: ...4 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 6 Installer Cache de poussoir c t admission 1 Joint torque 2 N B Enduire le joint torique de graisse base de...

Page 148: ...ee play Adjustment steps Loosen the locknuts 1 Turn the adjusters 2 in or out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the...

Page 149: ...n bis das vorgeschriebene Spiel erreicht ist Hineindrehen Spiel kleiner Herausdrehen Spiel gr er ACHTUNG Nach Einstellung des Fu bremshebel spiels darf die Bremse nicht schleifen PARTIE CYCLE REGLAGE...

Page 150: ...t chain position Drive chain slack 40 53 mm 1 6 2 1 in 3 Adjust Drive chain slack Drive chain slack adjustment steps Loosen the wheel axle nut 1 and locknuts 2 Adjust chain slack by turning the adjust...

Page 151: ...REGLAGEDELATENSIONDELACHAINEDETRANSMISSION ANTRIEBSKETTEN DURCHHANG EINSTELLEN REGLAGE DE LA TENSION DE LA CHAINE DE TRANSMISSION 1 Sur lever la roue arri re en pla ant un sup port ad quat sous le mo...

Page 152: ...e front brake and stroke the front fork Unsmooth action oil leakage Repair or replace EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the...

Page 153: ...ad vom Boden abzuheben 2 Demontieren Siehe unter SCHWINGE im KAPITEL 5 3 Demontieren Federsitz 1 HINWEIS Den Federsitz bei zusammengedr ckter Feder demontieren Serrer l crou d axe de roue tout en appu...

Page 154: ...ber Refer to SWINGARM section in the CHAPTER 5 EC36Q000 TIRE PRESSURE CHECK 1 Measure Tire pressure Out of specification Adjust NOTE Check the tire while it is cold Loose bead stoppers allow the tire...

Page 155: ...Reifen verrutscht ist Bei geneigtem Reifenventilschaft mu die Reifenposition berichtigt werden Standard Reifenluftdruck 100 kPa 1 00 kgf cm2 14 5 psi 4 Pour durcir la pr contrainte de ressort mon ter...

Page 156: ...After a practice or a race check spokes for looseness T R 2 Nm 0 2 m kg 1 4 ft lb EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2 Inspect Bear...

Page 157: ...fbocken um das Vorderrad vom Boden abzuheben 2 Kontrollieren Lenkkopf Die Gleitrohre am unteren Ende umfas sen und die Teleskopgabel wie gezeigt hin und her bewegen Spiel Einstellen INSPECTION ET SERR...

Page 158: ...t 2 using the ring nut wrench 3 Ring nut wrench YU 1268 90890 01268 Tighten the ring nut 4 using ring nut wrench 5 and turn the steering right and left a few times NOTE Set the torque wrench to the ri...

Page 159: ...ziehen T R Ringmutter endg ltiges Anzugsmoment 1 Nm 0 1 m kg 0 7 ft lb 3 Contr ler Fonctionnement en douceur de la direction Tourner le guidon de but e but e Fonctionnement dur R gler l crou annulaire...

Page 160: ...Nm 4 0 m kg 2 9 ft lb Handlebar upper holder 13 Nm 1 3 m kg 9 4 ft lb a b b TT R90E Steering ring nut Steering ring nut adjustment steps Remove the front fender 1 Remove the handlebar and handle crow...

Page 161: ...FOURCHE LENKKOPF KONTROLLIEREN UND EINSTELLEN Contr ler l arbre de direction en le tournant de but e but e S il y a le moindre point dur d monter la colonne de direction compl te et examiner les pali...

Page 162: ...mbly and inspect the steering bearings Install the handle crown 6 main switch 7 handlebar 8 and front fender NOTE Install the handlebar holder with its groove a facing outward The upper handlebar hold...

Page 163: ...9 ft lb Lenkerhalterung 40 Nm 4 0 m kg 2 9 ft lb Abdeckschraube 23 Nm 2 3 m kg 17 ft lb Desserrer l crou annulaire d un tour Resserrer l crou annulaire l aide de la cl pour crous annulaires AVERTISSEM...

Page 164: ...ke lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake cable end Use Yamaha cable lube or equ...

Page 165: ...Lithiumfett verwenden LUBRIFICATION Afin de garantir le bon fonctionnement de tous les l ments il convient de lubrifier la machine avant la premi re utilisation apr s le rodage ainsi qu apr s chaque c...

Page 166: ...ds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Cl...

Page 167: ...est anziehen a und dann erst vorschriftsm ig festziehen b T R 13 Nm 1 3 m kg 9 4 ft lb PARTIE ELECTRIQUE INSPECTION DE BOUGIE 1 D poser Bougie 2 Examiner Electrode 1 Usure endommagement Remplacer Coul...

Page 168: ...bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get imm...

Page 169: ...DE LA BATTERIE TT R90E BATTERIE KONTROLLIEREN UND LADEN TT R90E CONTROLE ET RECHARGE DE LA BATTERIE TT R90E AVERTISSEMENT Les batteries produisent de l hydrog ne qui est un gaz explosif et elles cont...

Page 170: ...lead coupler 1 from the battery terminals NOTE Push down on the tab a and then remove the battery lead coupler 3 Remove Battery 1 a 4 Measure Battery charge Measurement steps Connect a pocket tester 1...

Page 171: ...ng mindestens 12 8 V betr gt CONTROLE ET RECHARGE DE LA BATTERIE TT R90E BATTERIE KONTROLLIEREN UND LADEN TT R90E N B Comme une batterie MF est scell e il est impossi ble de v rifier son tat de charge...

Page 172: ...0 30 5 Charge Battery refer to the appropriate charging method illustration WARNING Do not quick charge a battery CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charge...

Page 173: ...T RECHARGE DE LA BATTERIE TT R90E BATTERIE KONTROLLIEREN UND LADEN TT R90E Relation entre la tension en circuit ouvert et le temps de charge 20 C 68 F Ces valeurs varient selon la temp rature l tat de...

Page 174: ...ct area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnect...

Page 175: ...sen CONTROLE ET RECHARGE DE LA BATTERIE TT R90E BATTERIE KONTROLLIEREN UND LADEN TT R90E Ne pas oublier de couper l alimentation du chargeur avant de retirer les pinces du char geur des bornes de la b...

Page 176: ...dard charging amperage exceeded NO YES If the amperage does not exceed the standard charg ing amperage after 5 min utes replace the battery If the required charging time exceeds 5 hours it is advisabl...

Page 177: ...reaches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the batter...

Page 178: ...r obtenir l amp rage de charge standard L amp rage est il sup rieur l amp rage standard de charge indiqu sur la batte rie R gler la tension de charge 20 25 V Surveiller l amp rage pendant 3 5 minutes...

Page 179: ...temps de charge pour un maximum de 20 heures Laisser reposer la batterie pendant 30 minutes avant de mesurer sa tension en circuit ouvert 12 8 V La charge est termin e 12 0 12 7 V Il est n cessaire d...

Page 180: ...nnung neu einstellen um die normale Ladestromst rke zu erhalten Ist die Amperezahl h her als die auf der Batterie abgegeben normalen Ladestromst rke Die Ladespannung auf 20 25 V stellen Die Stromst rk...

Page 181: ...en der Ruhespannung die Batterie ber 30 Minuten lang nicht benut zen 12 8 V Der Ladevorgang ist abgeschlos sen 12 0 12 7 V Die Batterie erneut laden Unter 12 0 V Die Batterie erneuern ACHTUNG Ladeger...

Page 182: ...Recommended lubricant Lithium soap base grease FUSE INSPECTION TT R90E CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Seat Rear fender 2...

Page 183: ...ultimeter YU 03112 C 90890 03112 Falls das Multimeter anzeigt die Sicherung erneuern INSPECTION DES FUSIBLES TT R90E SICHERUNGEN KONTROLLIEREN TT R90E 6 Monter Batterie 7 Contr ler Bornes de batterie...

Page 184: ...damage to the electrical system cause the starting and ignition systems to malfunction and could possibly cause a fire 4 Install Rear fender Seat Replacement steps Set the main switch to OFF Install a...

Page 185: ...ntsprechenden Stromkreis kontrollie ren Sicherung Ampere Anzahl Hauptsicherung 10 A 1 INSPECTION DES FUSIBLES TT R90E SICHERUNGEN KONTROLLIEREN TT R90E 3 Remplacer Fusible grill AVERTISSEMENT Ne jamai...

Page 186: ...ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank 1 Clamp air filter joint 1 Loosen the screw air filter joint 2 Carburetor heater lead 1 3 Air vent hose 1 4 Fuel hose 1 5 Bolt 2 6 Carbu...

Page 187: ...aser 1 7 O Ring 1 8 Distanzst ck 1 9 Vergaserdeckel 1 10 Choke Einrichtung 1 1 CARBURATEUR VERGASER MOTEUR CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre...

Page 188: ...disassembly Extent of removal Order Part name Q ty Remarks CARBURETOR DISASSEMBLY 1 Throttle valve 1 2 Throttle cable 1 3 Spring 1 4 Gasket 1 5 Carburetor top cover 1 6 Jet needle stopper 1 7 Jet nee...

Page 189: ...l 1 8 Choke 1 9 Chokezug 1 0 Schwimmerkammer 1 1 DEMONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DU CA...

Page 190: ...R Extent of removal Order Part name Q ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1 G Throttle stop screw assembly 1 H Pilot air screw assembly 1 I Carb...

Page 191: ...G Drosselklappen Anschlag schraube 1 H Leerlaufgemisch Regulier schraube 1 I Vergaserbeheizung 1 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques A Axe de flotteur 1 B Flotteur 1 C Pointea...

Page 192: ...jet 1 Pilot jet 2 Needle jet 3 Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire Needle valve 1 I...

Page 193: ...gigkeit Schwerg ngigkeit Instand setzen oder erneuern HINWEIS Das Gasschieber 1 in das Vergasergeh use einsetzen und auf Leichtg ngigkeit pr fen CONTROLE Carburateur 1 Contr ler Corps du carburateur E...

Page 194: ...the measurement when the needle valve aligns with the float arm If the carburetor is level the weight of the float will push in the needle valve result ing in an incorrect measurement Measure the dist...

Page 195: ...merhebels 1 einstellen Schwimmerh he erneut kontrollieren Aiguille 1 Contr ler Aiguille 1 D form e usure Changer Gorge de l agrafe Jeu usure Remplacer Position de clip Hauteur du flotteur 1 Mesurer Ha...

Page 196: ...rew until it is lightly seated Back out it by the specified number of turns Pilot air screw 1 3 4 turns out 2 Install Throttle valve 1 Starter plunger 2 NOTE Align the slit a of the throttle valve wit...

Page 197: ...toff Benzin und Kraftstoffdampf sind leicht entz ndlich und explosiv und m ssen deshalb von allen Feuerquellen wie Z ndfunken Zigaretten offenen Flam men etc ferngehalten werden Flotteur 1 Contr ler F...

Page 198: ...4 7 ENG CARBURETOR 1 Measure Fuel level a Use a fuel level gauge 1 Out of specification Adjust Fuel level gauge YM 1312 A 90890 01312 Fuel level 2 3 mm 0 08 0 12 in below the float chamber line...

Page 199: ...YM 1312 A 90890 01312 Schwimmerstand 2 3 mm 0 08 0 12 in unter halb der Schwimmerkammer Pa fl che 1 Mesurer Niveau de carburant a Utiliser une jauge de niveau de carburant 1 Hors sp cification R gler...

Page 200: ...d rear fender Exhaust pipe Carburetor Refer to CARBURETOR section Air filter case and starter lever 1 Plug cap spark plug 1 1 2 Crankshaft end cover O ring 1 1 3 Timing plug O ring 1 1 4 Camshaft spro...

Page 201: ...er AUSBAU 8 Steuerkettenspanner 1 9 Dichtung 1 1 CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE...

Page 202: ...4 9 ENG CYLINDER HEAD Extent of removal Order Part name Q ty Remarks 10 Camshaft sprocket 1 Refer to REMOVAL POINTS 11 Timing chain 1 12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2 1...

Page 203: ...cames 1 Se reporter POINTS DE DEPOSE 11 Cha ne de distribution 1 12 Culasse 1 13 Joint 1 14 Goujon 2 1 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 10 Nockenwellenrad 1 Siehe unter AUSBAU 1...

Page 204: ...enter T D C NOTE In order to be sure that the piston is at Top Dead Center the match mark c on the camshaft sprocket must align with the sta tionary pointer d on the cylinder head as shown in the illu...

Page 205: ...Kur belgeh use fallen kann Beim L sen der Schraube 1 die Lichtma schinenrotor Mutter mit einem Schrauben schl ssel festhalten POINTS DE DEPOSE Culasse 1 Aligner Rep re I avec l index fixe Etapes de la...

Page 206: ...ration Tighten the bolts and nuts in two stages T R 22 Nm 2 2 m kg 16 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Camshaft sprocket 1 Installation steps Turn the crankshaft counterclockwise until the...

Page 207: ...d chappement maintenir la cha ne de distribu tion aussi tendue que possible du c t chappe ment CULASSE ZYLINDERKOPF 4 Demontieren Zylinderkopf HINWEIS Die Schrauben und Muttern in der angege benen Rei...

Page 208: ...rk Align with the crankcase stationary pointer Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Installation steps Remove the tensioner cap bolt...

Page 209: ...Schraube samt Dichtung mit dem vorge schriebenen Drehmoment festziehen T R Steuerkettenspanner Verschlu schraube 8 Nm 0 8 m kg 5 8 ft lb ATTENTION Veiller ce que le vilebrequin reste immobile pendant...

Page 210: ...Q ty Remarks CAMSHAFT AND ROCKER ARMS Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Rocker arm shaft intake 1 Use special tool Refer to REMOVAL POINTS 2 Rocker arm shaft exha...

Page 211: ...llenlager Halter 1 5 Nockenwelle 1 6 Kontermutter Ventileinstell schraube 2 7 Ventileinstellschraube 2 1 2 ARBRE A CAMES ET CULBUTEURS Organisation de la d pose 1 Culbuteur 2 D pose de l arbre cames O...

Page 212: ...ide hammer bolt 90890 01085 Weight 90890 01084 INSPECTION Camshaft 1 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 25 398 mm 0 9999 in b 21 004 mm 0 826...

Page 213: ...GE 1 Auftragen Molybd ndisulfid l auf die Nocken Motor l auf die Nockenwellenlager 2 Montieren Nockenwelle 1 POINTS DE DEPOSE Axe de culbuteur 1 D poser Axes de culbuteur N B Se servir d un boulon d e...

Page 214: ...4 15 ENG CAMSHAFT AND ROCKER ARMS 3 Apply Molybdenum disulfide oil onto the rocker arm and rocker arm shaft 4 Install Rocker arm 1 Rocker arm shaft 2...

Page 215: ...LLE UND KIPPHEBEL 3 Auftragen Molybd ndisulfid l auf Kipphebel und Kipphebelwelle 4 Montieren Kipphebel 1 Kipphebelwelle 2 3 Appliquer Huile au bisulfure de molybd ne sur le culbuteur et l axe de culb...

Page 216: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Rocker arm and camshaft Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4 Use...

Page 217: ...ederteller 2 3 Ventilfeder 2 4 Ausla ventil 1 5 Einla ventil 1 6 Ventilschaftdichtung 2 1 SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la d pose 1 D pose des soupapes Organisation de la d pose Ordr...

Page 218: ...sor YM 4019 90890 04019 INSPECTION Valve 1 Measure Stem to guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Clea...

Page 219: ...vorschriftsm ig Erneuern Max zul ssiger Schlag 0 02 mm 0 0008 in POINTS DE DEPOSE D pose des soupapes 1 D poser Clavettes de soupape 1 N B Fixer un compresseur de ressort de soupape 2 entre la retenue...

Page 220: ...h a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps A...

Page 221: ...au er mittig mu der Ventilsitz nachbearbeitet werden Ressort de soupape 1 Mesurer Longueur libre du ressort de soupape a Hors sp cifications Remplacer 2 Mesurer Inclinaison du ressort a Hors sp cifica...

Page 222: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Page 223: ...ssen Entspricht die Ventilsitzbreite noch immer nicht dem Sollma den Ventilsitz nochmals nachbe arbeiten und einschleifen 2 Roder Face de soupape Si ge de soupape N B Apr s le surfa age du si ge de so...

Page 224: ...the embossed mark as follows Intake G Exhaust L Install the valve springs with the larger pitch a facing upwards b Smaller pitch New 3 Install Valve cotters NOTE While compressing the valve spring wi...

Page 225: ...as Ventilschaftende k nnen das Ventil besch digen ASSEMBLAGE ET MONTAGE 1 Appliquer Huile au bisulfure de molybd ne sur la queue de soupape et la bague d tan ch it de queue de soupape 2 Monter Bagues...

Page 226: ...ks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Timing chain guide exhaust 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pin clip 2 Use special...

Page 227: ...1 Kompressionsring Topring 1 Siehe unter AUSBAU 9 2 Kompressionsring 1 10 labstreifring Expander 2 1 2 1 CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Organisati...

Page 228: ...use the piston pin puller set 4 Piston pin puller set YU 1304 90890 01304 Piston ring 1 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top...

Page 229: ...ng C parallel zum und im rechten Winkel zur Kurbelwelle messen Danach den Durchschnitt der Messung bestimmen POINTS DE DEPOSE Piston 1 D poser Circlip d axe de piston 1 Axe de piston 2 Piston 3 N B Av...

Page 230: ...re the piston skirt diameter P with a micrometer a 4 mm 0 16 in from the piston bottom edge Piston size P Standard 46 960 46 975 mm 1 8488 1 8494 in If out of specification replace the piston and pist...

Page 231: ...15 mm 0 0059 in Falls unvorschriftsm ig den Zylinder erneuern und Kolben sowie Kolbenringe im Satz erneuern Al sage de cylindre C 47 000 47 005 mm 1 8504 1 8506 in Limite de conicit T 0 05 mm 0 002 i...

Page 232: ...crown so that the ring will be at a right angle to the cylinder bore a 5 mm 0 20 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of t...

Page 233: ...0 4 mm 0 016 in labstreif ring 0 2 0 7 mm 0 01 0 03 in Segment de piston 1 Mesurer Jeu lat ral du segment Utiliser une jauge d paisseur Hors sp cifications Remplacer la fois le piston et ses segments...

Page 234: ...gs so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Measurement steps Measure the piston pin outsi...

Page 235: ...5119 0 5123 in Grenzwert 13 045 mm 0 5136 in Axe de piston 1 Contr ler Axe de piston D coloration bleue gorges Remplacer puis examiner le syst me de graissage 2 Mesurer Diam tre ext rieur d axe de pi...

Page 236: ...nts to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate Piston Pisto...

Page 237: ...ger l amor tisseur de cha ne de distribution pendant l ins tallation Faire passer la cha ne de distribution travers la cavit de cha ne de distribution New 2 Montieren 1 Kompressionsring Topring 2 Komp...

Page 238: ...er Part name Q ty Remarks CRANKCASE COVER LEFT AND RIGHT REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Shift pedal 1 2 Drive sprocket...

Page 239: ...5 Pa stift 2 6 Kupplungseinstellschraube 1 7 Kickstarterhebel 1 8 Kurbelgeh usedeckel rechts 1 9 Dichtung 1 10 Pa stift 2 2 1 EMBRAYAGE DEMI CARTERS GAUCHE ET DROIT Organisation de la d pose 1 D pose...

Page 240: ...removal Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL 1 Bolt clutch spring 4 4 2 Pressure plate 1 3 Washer 1 4 Push rod 1 1 5 Friction plate 5 6 Clutch plate 4 7 Push rod 2 1 8 Clutch...

Page 241: ...be 1 10 Kupplungsnabe 1 11 Unterlegscheibe 1 12 Kupplungskorb 1 3 1 2 EMBRAYAGE Organisation de la d pose 1 D pose des disques de friction et des disques d embrayage 2 D pose du carter d embrayage 3 D...

Page 242: ...me Q ty Remarks 13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool Refer to REMOVAL POINTS 16 Washer 1 17 Spacer 1 18 Primary clutch housing 1 19 Primary clutch boss 1 20 Clutch carrier...

Page 243: ...19 Prim rkupplungsnabe 1 20 Kupplungskorb 1 21 Ausr cklager 1 22 Unterlegscheibe 1 3 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 13 Entretoise 1 14 Entretoise 1 15 Ecrou d embrayage pr...

Page 244: ...lutch holding tool YM 91042 90890 04086 Primary clutch 1 Remove Primary clutch nut 1 NOTE Loosen the nut while holding the magneto rotor with the sheave holder 2 INSPECTION EC484500 Friction plate 1 M...

Page 245: ...benst rke Standard Grenzwert 2 7 2 9 mm 0 106 0 114 in 2 6 mm 0 102 in POINTS DE DEPOSE Noix d embrayage 1 D poser Ecrou 1 Rondelle frein 2 Noix d embrayage N B Redresser la rondelle frein et utiliser...

Page 246: ...sure Push rod 2 bend Out of specification Replace Warp limit 0 2 mm 0 008 in Clutch spring free length Standard Limit 26 2 mm 1 03 in 24 2 mm 0 95 in Bending limit 0 5 mm 0 02 in Primary clutch 1 Meas...

Page 247: ...ungsbelag Nut 1 0 1 3 mm 0 039 0 051 in Grenzwert 0 1 mm 0 004 in Disques d embrayage 1 Mesurer Voile de disque d embrayage Hors sp cification Changer tous les dis ques d embrayage Utiliser une plaque...

Page 248: ...ing tool 3 to hold the clutch boss For USA and CDN Except for USA and CDN 2 Bend Lock washer tab Sheave holder YS 1880 A 90890 01701 Clutch holding tool YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft l...

Page 249: ...r leicht fest sitzt Um 1 8 Drehung ausdrehen Die Kontermutter festziehen T R Kontermutter 8 Nm 0 8 m kg 5 8 ft lb ASSEMBLAGE ET MONTAGE Embrayage primaire 1 Installer Rondelle 1 Ecrou embrayage primai...

Page 250: ...name Q ty Remarks KICK AXLE REMOVAL AND DISASSEMBLY Preparation for removal Crankcase cover right Refer to CLUTCH section 1 Kick axle assembly 1 2 Circlip 2 3 Spring cover 1 4 Torsion spring 1 5 Sprin...

Page 251: ...erungsring 1 9 Sicherungsring 1 10 Unterlegscheibe Spezialscheibe 1 1 11 Kickstarterzahnrad 1 12 Kickstarterwelle 1 2 1 ARBRE DE KICK Organisation de la d pose 1 D pose de l arbre de kick pied 2 D mon...

Page 252: ...HAFT REMOVAL Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section 1 Shift fork guide bar 1 2 Shift arm 3 1 3 Plate washer 1 4 Compression spring 1 5 Shift guide 1 6 Ball h...

Page 253: ...ger 1 11 Sicherungsring 1 12 Schaltarm komplett 1 13 Schaltwelle 1 1 ARBRE DE SELECTION Organisation de la d pose 1 Depose de l arbre de selection Organisation de la d pose Ordre Nom de pi ce Qt Remar...

Page 254: ...4 35 ENG SHIFT SHAFT Extent of removal Order Part name Q ty Remarks 14 Stopper lever 1 15 Torsion spring 1 16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1 1...

Page 255: ...4 Rastenhebel 1 15 Torsionsfeder 1 16 Sicherungsring 1 17 Tellerscheibe 1 18 Torsionsfeder 1 19 Schaltarm 1 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 14 Levier de but e 1 15 Ressort...

Page 256: ...ty Remarks OIL PUMP REMOVAL AND DIS ASSEMBLY Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section Shift shaft Refer to SHIFT SHAFT section 1 Rotary filter 1 2 Oil pump as...

Page 257: ...rad 1 8 Federring 1 9 Sicherungsring 1 10 Beilagscheibe 1 2 1 3 POMPE A HUILE Organisation de la d pose 1 D pose de la pompe huile 2 D pose de la cr pine huile 3 D montage de la pompe huile Organisati...

Page 258: ...4 37 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 11 Oil pump cover 1 12 Dowel pin 2 13 Oil pump drive shaft 1 14 Pin 1 15 Inner rotor 1 16 Outer rotor 1 17 Rotor housing 1 3...

Page 259: ...ift 2 13 lpumpen Antriebswelle 1 14 Stift 1 15 Innenrotor 1 16 Au enrotor 1 17 Rotorgeh use 1 3 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11 Couvercle de pompe huile 1 12 Goujon 2 13 A...

Page 260: ...ce the oil pump assembly Tip clearance a 0 15 mm 0 0059 in Limit 0 2 mm 0 0079 in Side clearance b 0 13 0 18 mm 0 0051 0 0071 in Limit 0 23 mm 0 0091 in Rotor housing and rotor clear ance c 0 06 0 10...

Page 261: ...kierung a auf dem Zentrifugalfilter auf die Bohrung b in der Kurbelwelle ausrichten CONTROLE Pompe a huile 1 Mesurer Jeu en bout a entre rotors int rieur 1 et ext rieur 2 Jeu lat ral b entre le rotor...

Page 262: ...removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover left Refer to CLUTCH section 1 CDI magneto coupler 1 2 Pickup coil stator assembl...

Page 263: ...e d excitation stator 1 3 Ecrou de rotor 1 Utiliser un outil sp cial Se reporter POINTS DE DEPOSE 4 Rotor 1 5 Clavette de demi lune 1 1 2 CDI SCHWUNGRADMAGNETZ NDER TT R90 Demontage Arbeiten 1 Indukti...

Page 264: ...otor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel puller and the rotor i...

Page 265: ...wellenzapfen zum Schutz mit dem Steckschl ssel abdecken Polrad Abzieher YU 33270 B 90890 01362 MAGNETO CDI TT R90 CDI SCHWUNGRADMAGNETZ NDER TT R90 POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Ro...

Page 266: ...gear removal Extent of removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover left Refer to CLUTCH section 1 CDI magneto coupler 1 2 Pic...

Page 267: ...Siehe unter AUSBAU 4 Rotor 1 5 Scheibenfeder 1 6 Welle 1 7 Leerlaufrad 1 8 Starterkupplung Getrieberad 1 1 1 2 3 MAGNETO CDI ET ROCHET DE DEMARRAGE TT R90E Organisation de la d pose 1 D pose de la bo...

Page 268: ...1880 A 90890 01701 2 Remove Rotor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the fl...

Page 269: ...rden um die Position des Schwungradabziehers anzupassen ACHTUNG Kurbelwellenzapfen zum Schutz mit dem Steckschl ssel abdecken Polrad Abzieher YU 33270 B 90890 01362 POINTS DE DEPOSE Rotor 1 D poser Ec...

Page 270: ...er clutch When turning the starter wheel gear clock wise the starter clutch and the starter wheel gear should be engaged If not the starter clutch is faulty Replace it When turning the starter wheel g...

Page 271: ...AGE TT R90E CDI MAGNETZ NDER UND STARTERKUPPLUNG TT R90E INSPECTION Rochet de d marrage 1 Inspecter Dent du pignon de ralenti du d marreur a Dent du pignon d entra nement du d mar reur b Dent de la ro...

Page 272: ...Woodruff key 1 Rotor 2 NOTE Clean the tapered portion of the crankshaft and the magneto hub When installing the magneto rotor make sure the woodruff key is properly seated in the key way of the cranks...

Page 273: ...0 A 90890 01701 T R 48 Nm 4 8 m kg 35 ft lb MAGNETO CDI ET ROCHET DE DEMARRAGE TT R90E CDI MAGNETZ NDER UND STARTERKUPPLUNG TT R90E 3 Installer Ressort 1 Capuchon de ressort 2 Cheville 3 4 Installer R...

Page 274: ...t pipe Air filter case Carburetor Refer to CARBURETOR section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine guard and drive sprocket Engine assembly From the cha...

Page 275: ...pp lungskorb Siehe unter KUPPLUNG Kickstarter Siehe unter KICKSTARTERWELLE CARTER ET VILEBREQUIN Organisation de la d pose Ordre Nom de pi ce Qt Remarques SEPARATION DES DEMI CAR TERS ET DEPOSE DU VIL...

Page 276: ...to SHIFT SHAFT section Oil pump and oil strainer Refer to OIL PUMP section Rotor for the TT R90 Refer to CDI MAGNETO section for the TT R90 Rotor and starter clutch for the TT R90E Refer to CDI MAGNET...

Page 277: ...ion admission 1 2 Cha ne de distribution 1 3 Bride 1 TT R90E 4 Carter droit 1 5 Goujon 2 6 Vilebrequin 1 7 Carter gauche 1 1 2 3 CARTER ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Demontage Arbeiten...

Page 278: ...limit 0 03 mm 0 0012 in Side clearance 0 10 0 40 mm 0 0039 0 0157 in Radial clearance 0 010 0 025 mm 0 0004 0 0010 in 0 05 mm 0 002 in Crack width 42 95 43 00 mm 1 691 1 693 in ASSEMBLY AND INSTALLAT...

Page 279: ...darauf geachtet werden da kein Dichtmittel in den lkanal a gelangt Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 CONTROLE Vilebrequin 1 Mesurer Limite de faux rond a Jeu lat ral d...

Page 280: ...le disassembly Extent of removal Order Part name Q ty Remarks SHIFT FORK SHIFT CAM TRANSMISSION REMOVAL Preparation for removal Engine assembly Separate the crankcase Refer to CRANKCASE AND CRANK SHAF...

Page 281: ...gswelle zerlegen 1 6 Ausgangswelle zerlegen 1 7 Ritzel 2 Gang 1 8 Sicherungsring 1 9 Unterlegscheibe 1 1 2 FOURCHETTES DE SELECTION TAMBOUR ET BOITE DE VITESSES Organisation de la d pose 1 D pose des...

Page 282: ...ANSMISSION Extent of removal Order Part name Q ty Remarks 10 3rd pinion gear 1 11 Main axle 1 12 Circlip 1 13 Washer 1 14 Collar 1 15 1st wheel gear 1 16 3rd wheel gear 1 17 Circlip 1 18 Washer 1 19 2...

Page 283: ...nterlegscheibe 1 14 Distanzh lse 1 15 Zahnrad 1 Gang 1 16 Zahnrad 3 Gang 1 17 Sicherungsring 1 18 Unterlegscheibe 1 19 Zahnrad 2 Gang 1 20 Ausgangswelle 1 2 3 Organisation de la d pose Ordre Nom de pi...

Page 284: ...ully Note the posi tion of each part Pay particular attention to the location and direction of shift forks ASSEMBLY AND INSTALLATION Transmission shift cam shift fork 1 Install Main axle assembly 1 Dr...

Page 285: ...gschaltung Funktion des Getriebes Ungleichm iger Betrieb Reparie ren POINTS DE DEPOSE Fourchettes de s lection tambour et bo te vitesses 1 D poser Fourchettes Tambour Arbre secondaire complet Arbre pr...

Page 286: ...t name Q ty Remarks FRONT WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the e...

Page 287: ...RIERE VORDER UND HINTERRAD PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT ET FREIN AVANT Organisation de la d pose 1 D pose de la roue avant 2 D pose du roulement de roue 3 D pose et d montage du...

Page 288: ...5 2 CHAS Extent of removal Order Part name Q ty Remarks 10 Brake shoe 2 11 Brake camshaft lever 1 12 Brake camshaft 1 3 FRONT WHEEL AND REAR WHEEL...

Page 289: ...Anz Bemerkungen 10 Bremsbacken 2 11 Bremswellenhebel 1 12 Bremswelle 1 3 ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD Organisation de la d pose Ordre Nom de pi ce Qt Remarques 10 M choire de frein...

Page 290: ...name Q ty Remarks REAR WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the eng...

Page 291: ...e rechts 1 10 Bremsankerplatte 1 2 3 1 ROUE ET FREIN ARRIERE Organisation de la d pose 1 D pose de la roue arri re 2 D pose du roulement de roue 3 D pose et d montage du flasque et des m choires de fr...

Page 292: ...HEEL AND REAR WHEEL Extent of removal Order Part name Q ty Remarks 11 Collar left 1 12 Wheel drive hub assembly 1 13 Bearing 2 Refer to REMOVAL POINTS 14 Brake shoe 2 15 Brake camshaft lever 1 16 Brak...

Page 293: ...hmernabe komplett 1 13 Lager 2 Siehe unter AUSBAU 14 Bremsbacke 2 15 Bremswellenhebel 1 16 Bremswelle 1 3 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11 Collerette gauche 1 12 Moyeu d...

Page 294: ...eel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in Brake lining 1 Inspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper NOTE After polishing wipe the polished part...

Page 295: ...elbremsbelag St rke a Standard vorne 3 0 mm 0 12 in hinten 4 0 mm 0 16 in Grenzwert 2 0 mm 0 08 in POINTS DE DEPOSE Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement en ut...

Page 296: ...e securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Hand...

Page 297: ...lbr cke 1 Nur lockern 5 Teleskopgabel 1 1 FOURCHE AVANT Organisation de la d pose 1 D pose de la fourche avant Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration pour la d pose DEPO...

Page 298: ...val Extent of removal Order Part name Q ty Remarks FRONT FORK DISASSEMBLY Preparation for disas sembly Drain the fork oil 1 Adjuster 1 2 Fork spring 1 3 Dust cover 1 4 Stopper ring 1 5 Bolt damper rod...

Page 299: ...unter AUSBAU 6 Gleitrohr 1 7 D mpferrohr 1 8 Dichtring 1 9 Standrohr 1 1 2 DEMONTAGE DE LA FOURCHE AVANT Organisation de la d pose 1 D pose de la bague d tanch it 2 D pose de la tige d amortisseur Or...

Page 300: ...5000 ASSEMBLY AND INSTALLATION Front fork assembly 1 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver weight 2 and fork seal driver attachment 3 2 Fill Fork oil 3 A...

Page 301: ...gleichwertig FOURCHE AVANT TELESKOPGABEL POINTS DE DEPOSE Tube plongeur 1 D poser Boulon tige d amortisseur N B Desserrer le boulon de la tige d amortisseur tout en maintenant la tige d amortisseur l...

Page 302: ...Remarks HANDLEBAR REMOVAL 1 ENGINE STOP switch 1 2 Brake lever cable 1 Disconnect at the lever side 3 Brake lever 1 4 Grip cap lower 1 5 Grip cap upper 1 6 Throttle cable 1 Disconnect at the throttle...

Page 303: ...e commande des gaz 1 9 Poign e gauche 1 10 Demi palier de guidon sup rieur 2 11 Guidon 1 12 Demi palier de guidon inf rieur 2 1 LENKER TT R90 Demontage Arbeiten 1 Lenker demontieren Demontage Arbeiten...

Page 304: ...1 Main switch 1 2 Start switch 1 3 ENGINE STOP switch 1 4 Brake lever cable 1 Disconnect at the lever side 5 Brake lever 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle cable 1 Disconnect at the th...

Page 305: ...nks 1 12 Lenkerhalterung oben 2 13 Lenker 1 14 Lenkerhalterung unten 2 1 TT R90E Organisation de la d pose 1 D pose du guidon Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DU GUIDON...

Page 306: ...s STEERING REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front fork Refe...

Page 307: ...au en 2 2 1 DIRECTION Organisation de la d pose 1 D pose du t de fourche inf rieur 2 D pose du roulement ETAPES DE SERRAGE Serrer l crou cr nel un couple d environ 38 Nm 3 8 m kg 27 ft lb Le desserrer...

Page 308: ...chine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section R...

Page 309: ...tenschutztr ger 1 1 2 BRAS OSCILLANT Organisation de la d pose 1 D pose du bras oscillant 2 D pose de l amortisseur arri re Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DU BRAS OSC...

Page 310: ...5 13 CHAS SWINGARM Extent of removal Order Part name Q ty Remarks 9 Cotter pin 1 10 Nut tension bar 1 11 Bolt tension bar 1 12 Tension bar 1 1...

Page 311: ...nt 1 10 Mutter Bremsankerstrebe 1 11 Schraube Bremsankerstrebe 1 12 Bremsankerstrebe 1 1 BRAS OSCILLANT SCHWINGE Organisation de la d pose Ordre Nom de pi ce Qt Remarques 9 Goupille fendue 1 10 Ecrou...

Page 312: ...plug 5 ENGINE STOP switch 6 Thermo switch 7 Carburetor heater 8 Rectifier regulator COLOR CODE B Black Br Brown G Green O Orange R Red W White EC612000 WIRING DIAGRAM G W B R W L W R Br G R W W B Y R...

Page 313: ...B schwarz Br braun G gr n O orange R rot W wei B R schwarz rot B W schwarz wei G W gr n wei W L wei blau W R wei rot SCHALTPLAN PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE TT R90 COM...

Page 314: ...rting circuit cut off relay COLOR CODE B Black Br Brown G Green O Orange R Red Sb Sky blue W White Y Yellow EC612000 WIRING DIAGRAM G W B R W L W R Br G R W B W Br B R B W B Br R B W B B B B R W Br B...

Page 315: ...ot Y R gelb rot SCHALTPLAN COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN TT R90E COMPOSANTS ELECTRIQUES 1 Commutateur principal 2 Coupe circuit du moteur 3 Thermocont...

Page 316: ...ng special tools in this inspection Spark gap test Clean or replace spark plug Check entire ignition system for connection Repair or replace Check main switch TT R90E only Replace Check ENGINE STOP sw...

Page 317: ...de longueur d tincelle Nettoyer ou changer la bougie Contr ler les connexions du sys t me entier d allumage R parer ou changer Contr ler le commutateur principal TT R90E seulement Changer Contr ler le...

Page 318: ...ern oder instand setzen Hauptschalter pr fen Nur TT R90E Erneuern Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuern Sekund r spule Erneuern CDI Schwungradmagnet z...

Page 319: ...ELEC MEMO...

Page 320: ...ap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit...

Page 321: ...e bougie de la bougie 2 Connecter le testeur dynamique d tincelle 1 testeur d allumage 2 comme indiqu Capuchon de bougie 3 Bougie 4 Pour les USA et le CDN Except pour les USA et le CDN 3 Actionner le...

Page 322: ...ntinuous while being free Replace TT R90 TT R90E EC626002 IGNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace Tester lead Black White lead 1 Tester lead Black lead...

Page 323: ...schwarz 2 Prim rspulen Widerstand Me ger t Einstellung 0 18 0 28 bei 20 C 68 F 1 CONTROLE DU COUPE CIRCUIT DU MOTEUR TT R90 1 V rifier Continuit du coupe circuit du moteur Pas de continuit lorsqu enf...

Page 324: ...ce Tester selector position 6 3 9 5 k at 20 C 68 F k 1 CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specification Replace 2 Inspect Source coil resistance Out of specification Replac...

Page 325: ...gerspule Widerstand Me ger t Einstellung 688 1 032 bei 20 C 68 F 100 2 V rifier R sistance de bobine secondaire Hors sp cification Changer N B Pour contr ler la r sistance de la bobine secon daire enl...

Page 326: ...operating when this condi tion has not been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When the above condition has been met the starting...

Page 327: ...E TT R90E ELEKTROSTARTERSYSTEM TT R90E SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E FONCTIONNEMENT DU SYSTEME DE COUPURE DU CIRCUIT DE DEMARRAGE Si le contacteur cl est plac sur ON le d mar reur ne fonctio...

Page 328: ...in this inspection Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check ea...

Page 329: ...ur ce contr le Utiliser les outils sp ciaux suivants pour ce contr le Multim tre YU 3112 C 90890 03112 1 Contr ler le fusible Changer le fusible et v rifier le faisceau de fils 2 Contr ler la batterie...

Page 330: ...kzeuge verwenden Taschen Multimeter YU 3112 C 90890 03112 1 Sicherung pr fen Sicherung erneuern und Kabelbaum pr fen 2 Batterie pr fen Neu aufladen oder erneuern Alle Leitungsstecker und Kabelverbindu...

Page 331: ...ELEC MEMO...

Page 332: ...same capacity or more as that of the a battery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity STARTING CIRCUIT...

Page 333: ...tellung An Batterie angeschlos sen 1 Nicht an Batterie angeschlos sen SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E ELEKTROSTARTERSYSTEM TT R90E INSPECTION DE LA CONNEXION DES RACCORDS ET DES FILS 1 Contr l...

Page 334: ...relay terminal 2 Tester lead Starter relay terminal 3 Tester lead Starter relay terminal 4 Ter minal 3 Ter minal 4 Tester selec tor position Connected to battery 1 Not connected to battery NEUTRAL SW...

Page 335: ...GELEGT SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E ELEKTROSTARTERSYSTEM TT R90E INSPECTION DU RELAIS DE DEMARREUR 1 D poser Relais de d marreur 2 Inspecter Conducteur de relais de d marreur Utiliser une b...

Page 336: ...Start switch continuity No continuous while being pushed Replace Continuous while being freed Replace Tester lead Black lead 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PUSH IN 1 FRE...

Page 337: ...B 2 Me ger t Einstellung GE DR CKT 1 FREI SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E ELEKTROSTARTERSYSTEM TT R90E INSPECTION DU COMMUTATEUR DE DEMARRAGE 1 Inspecter Continuit du commutateur de d marrage...

Page 338: ...e Q ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Starter motor 1 STARTER MOTOR DISASSEM BLY 1 Front bracket...

Page 339: ...5 St nder Baugruppe 1 1 SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E ELEKTROSTARTERSYSTEM TT R90E MOTEUR DE D MARREUR Organisation de la d pose 1 D montage du moteur d demarreur Organisation de la d pose O...

Page 340: ...ensure proper operation of com mutator Commutator wear limit 16 6 mm 0 65 in Mica undercut 1 35 mm 0 05 in 4 Measure Armature assembly resistance com mutator and insulation Out of specification Repla...

Page 341: ...in Widerstand unvorschriftsm ig ist den Startermotor erneuern SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E ELEKTROSTARTERSYSTEM TT R90E INSPECTION ET REPARATION 1 Inspecter Commutateur Sale Nettoyer avec d...

Page 342: ...n Replace as a set Brush spring force 3 92 5 88 N 400 600 g 14 1 21 2 oz ASSEMBLY 1 Install Brush holder 2 Install Armature coil 1 3 Install Ring 1 Stator assembly 2 Front bracket 3 NOTE Apply molybde...

Page 343: ...m Joch mit der Pa markierung B gel ausrichten SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E ELEKTROSTARTERSYSTEM TT R90E 5 Mesurer Longueur des balais a Hors sp cification Changer Limite d usure des balais...

Page 344: ...ng parts before inspection 1 Seat 2 Rear fender 3 Fuel tank Use the following special tool in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890...

Page 345: ...arri re 3 R servoir essence Utiliser l outil sp cial suivant pour le contr le Multim tre YU 3112 C 90890 03112 Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 1 V rifier le fusible Cha...

Page 346: ...folgenden Spezialwerkzeuge verwenden Taschen Multimeter YU 3112 C 90890 03112 Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 1 Sicherung pr fen Sicherung erneuern und Kabelbaum pr fen 2...

Page 347: ...ELEC MEMO...

Page 348: ...of specification If no failure is found in checking the source coil resis tance replace the rectifier regulator Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester selector positio...

Page 349: ...t Einstellung 0 64 0 96 bei 20 C 68 F 1 SYSTEME DE RECHARGE TT R90E LADESYSTEM TT R90E INSPECTION DE LA CONNEXION DES RACCORDS ET DES FILS 1 Contr ler Connexion des raccords et des fils Rouille poussi...

Page 350: ...e the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Check entire carburetor heating system for connec tion Repair or replace Check thermo swit...

Page 351: ...tage des pannes 1 Selle 2 R servoir de carburant Utiliser les outils sp ciaux suivants dans ce d pistage des pannes Contr ler les connexions de l int gralit du syst me de r chauffement du carburateur...

Page 352: ...es Spezialwerkzeug verwenden Kabelanschl sse des gesamten Vergaserbehei zungssystems kontrollieren Erneuern oder instand setzen Thermoschalter kontrollieren Erneuern Vergaserbeheizung kontrollieren Er...

Page 353: ...ELEC MEMO...

Page 354: ...ion Replace Inspection steps Remove the thermo switch Connect the pocket tester to the thermo switch coupler as shown Tester lead Black 1 Tester lead Black 2 Immerse the thermo switch in a container f...

Page 355: ...alter auf Durchgang laut Tabelle kontrollieren TT R90 TT R90E SYSTEME DE RECHAUFFEMENT DU CARBURATEUR VERGASERBEHEIZUNGSSYSTEM CONTROLE DES CONNEXIONS DE COUPLEURS ET FILS 1 Contr ler Connexion de cou...

Page 356: ...re than 16 3 C 60 8 5 4 F NO 3 TT R90 More than 12 4 C 53 6 7 2 F TT R90E More than 11 3 C 51 8 5 4 F NO 4 TT R90 Less than 12 4 C 53 6 7 2 F TT R90E Less than 11 3 C 51 8 5 4 F YES Test steps 1 2 Hea...

Page 357: ...r erneuert werden Funktion des Thermoschalters kontrollieren SYSTEME DE RECHAUFFEMENT DU CARBURATEUR VERGASERBEHEIZUNGSSYSTEM Le circuit du thermocontact est ouvert Le circuit du thermocontact est fer...

Page 358: ...Carburetor heater body 2 Carburetor heater resistance Tester selector position 6 10 at 20 C 68 F 1 CDI MAGNETO INSPECTION 1 Inspect Lighting coil resistance Out of specification Replace TT R90 TT R90E...

Page 359: ...C 68 F 1 SYSTEME DE RECHAUFFEMENT DU CARBURATEUR VERGASERBEHEIZUNGSSYSTEM CONTROLE DU RECHAUFFEUR DE CARBURATEUR 1 V rifier R sistance du r chauffeur de carburateur Hors sp cifications Changer Pointe...

Page 360: ...rdance with the emission warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of mainte nance work MAINTE NANCE INTERVAL DATE...

Page 361: ...a garantie du syst me antipollution Le seul but du tableau ci dessous est de rappeler l utilisateur que l entretien doit tre effectu Il ne constitue pas une preuve que l entretien a t effectu PROGRAMM...

Page 362: ...doku mentieren Die untenstehende Tabelle dient nur als Erinnerung daran da die Wartungsarbeiten durchgef hrt werden m ssen Sie ist kein anerkannter Beleg f r die Durchf hrung der Wartungsar beiten Wa...

Page 363: ......

Page 364: ...PRINTED IN JAPAN 2003 03 0 5 1 CR E F G PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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Yamaha TT-R90(S), Owner'S Service Manual

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