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Yamaha TT-R90(V) Owner'S Service Manual Download Page 106

2 - 13

SPEC

WARTUNGSDATEN

HINWEIS:

• 1. Die Ringmutter mit dem Hakenschlüssel auf ca. 38 Nm (3,8 m • kg, 27 ft • lb) festziehen;

danach den Lenker mehrmals beidseitig schwenken und dann die Ringmutter um eine Umdre-
hung lösen.

2. Die Ringmutter um 1 Nm (0,1 m • kg, 0,7 ft • lb) weiter anziehen.

•

: Anzugsmoment nach dem Einfahren und vor jeder Fahrt kontrollieren.

Festzuziehendes Teil

Gewinde-

größe

Anz.

Anzugsmoment

Nm

m·kg

ft·lb

Motorlager

Motor und Rahmen (vorn oben)

M8 

×

 1,25

1

30

3,0

22

Motor und Rahmen (hinten oben)

M8 

×

 1,25

1

26

2,6

19

Motor und Rahmen (hinten unten)

M10 

×

 1,25

1

48

4,8

35

Chokezug und Rahmen

M11 

×

 1,25

1

1

0,1

0,7

Schwingenachse und -Mutter

M10 

×

 1,25

1

30

3,0

22

Obere Gabelbrücke und Lenkkopf

M10 

×

 1,25

1

40

4,0

29

Gabel-Abdeckschraube

M20 

×

 1,0

2

40

4,0

29

Untere Gabelbrücke und Gabelholme

M10 

×

 1,25

2

33

3,3

24

Dämpferrohr-Schraube

M8 

×

 1,25

2

20

2,0

14

Obere Gabelbrücke und Lenkerhalter (unten)

M10 

×

 1,25

2

40

4,0

29

Lenkerhalter (oben) (TT-R90)

M6 

×

 1,0

4

13

1,3

9,4

(TT-R90E)

M8 

×

 1,25

4

23

2,3

17

Vorderrad-Bremszughalterung und Gabel-
holme

M6 

×

 1,0

2

7

0,7

5,1

Ringmutter

M25

1

Siehe unter HINWEIS.

Kraftstofftank und -hahn

M6 

×

 1,0

2

7

0,7

5,1

Kraftstofftank und Rahmen

M6 

×

 1,0

2

7

0,7

5,1

Haltegriff und Rahmen

M6 

×

 1,0

4

13

1,3

9,4

Handbremshebel-Schraube

M6 

×

 1,0

1

3

0,3

2,2

Handbremshebel-Mutter

M6 

×

 1,0

1

4

0,4

2,9

Vorderrad-Bremswellenhebel und -Brems-
welle

M6 

×

 1,0

1

7

0,7

5,1

Hinterrad-Bremswellenhebel und -Bremswelle

M6 

×

 1,0

1

7

0,7

5,1

Vorderachs-Mutter

M10 

×

 1,25

1

35

3,5

25

Hinterrad-Bremsankerplatte und Zugstange

M8 

×

 1,25

2

26

2,6

19

Mitnehmernabe und Kettenrad

M8 

×

 1,25

4

25

2,5

18

Hinterachs-Mutter

M12 

×

 1,25

1

60

6,0

43

Speichennippel

—

64

2

0,2

1,4

Antriebskettenschutz

M5 

×

 0,8

2

4

0,4

2,9

Antriebskettenschiene

M5 

×

 0,8

3

4

0,4

2,9

Kettenspanner-Sicherungsmutter

M6 

×

 1,0

2

7

0,7

5,1

Fußraste und Rahmen

M8 

×

 1,25

2

30

3,0

22

Batteriekasten (TT-R90E)

M6 

×

 1,0

3

5

0,5

3,6

Summary of Contents for TT-R90(V)

Page 1: ...0E V OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH PRINTED IN JAPAN 2005 04 0 3 1 CR E F G TT R90 V TT R90E V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 S...

Page 2: ...V OWNER S SERVICE MANUAL 2005 by Yamaha Motor Co Ltd 1st Edition April 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly pr...

Page 3: ...auch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R90 V TT R90E V MANUEL D ATELIER DU PROPRIETAIRE 2005 Yamaha Motor Co Ltd 1re dition a...

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: ...GESTATTET DIESES FAHRZEUG IST AUSSCHLIESS LICH F R DEN EINSATZ IM GEL NDE VORGESEHEN DER GEBRAUCH AUF FFENTLICHEN STRASSEN IST NICHT ZUL SSIG INTRODUCTION F licitations au propri taire de la TT R90 T...

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: ...k nnte umfallen SICHERHEITSINFORMATION NOTE IMPORTANTE Ce v hicule est con u uniquement pour une utilisa tion tout terrain par des pilotes tr s jeunes roulant sous la surveillance d un adulte apr s a...

Page 8: ...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 poison ous and may cause loss of con sciousness and death wit...

Page 9: ...Motorradbekleidung Hand schuhe Stiefel Hose und Jacke tra gen 4 Lors du transport de la moto dans un autre v hicule veiller le garder bien droit et ce que le robinet de carburant soit sur OFF Si le v...

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: ...tz 4 Handschuhe 5 Stiefel 6 Motocross Hose 7 Lang rmeliges Hemd 1 Ne pas rouler sur la route INFORMATION DE SECURITE 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il s agit d une moto une seule...

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: ...10 Vor dem Anlassen sicherstellen dass das Getriebe in der Leerlaufstellung ist 6 Toujours partir moto avec un parent ou ins tructeur Ne jamais partir seul 7 Avant de rouler demander ce qu un instruc...

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

Page 15: ...rn COMMENT UTILISER CE MANUEL INFORMATIONS PARTICULIE REMENT IMPORTANTES Le symbole d alerte de s curit signifie ATTENTION SOYEZ VIGILANT VOTRE SECURITE EST EN JEU Le non respect des instructions AVER...

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: ...Informati onen ben tigen werden zus tzlich zur Explosionszeichnung und T tigkeits ber sicht erg nzende Schrittfolgen 6 aufge f hrt FORMAT DU MANUEL Dans ce manuel toutes les proc dures sont d crites p...

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: ...zu versehen sind I Klebemittel LOCTITE auftragen J Erneuern SYMBOLES GRAPHIQUES Voir l illustration Les symboles graphiques 1 6 servent a rep rer les diff rents chapitres et indiquer leur contenu 1 R...

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

Page 21: ...PEC 2 REGELM SSIGE WARTUNGS 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 PERIODI...

Page 22: ...12 STARTING AND OPERATION 1 13 CLEANING AND STORAGE 1 14 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITION OF UNITS 2 17...

Page 23: ...TINEKONTROLLE VOR FAHRTBEGINN 3 3 MOTOR 3 4 FAHRWERK 3 12 ELEKTRISCHE ANLAGE 3 23 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS GENERAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MOTO 1 2 INFORMATIONS IMPO...

Page 24: ...NETO 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 10 HANDLEBAR 5 13 STEERING 5...

Page 25: ...6 17 VERZEICHNIS DER WARTUNGSARBEITEN 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 EMBRAYAGE 4 27 AR...

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: ...und technischen Daten jederzeit vorbehalten Das abgebildete Modell ist TT R90E DESCRIPTION FAHRZEUGBESCHREIBUNG RENSEIGNEMENTS GENERAUX DESCRIPTION 1 Coupe circuit du moteur 2 Contacteur cl TT R90E 3...

Page 28: ...achine 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 I...

Page 29: ...t Die Codenummer und das Info K rzel werden zur Ersatzteilbestellung ben tigt IDENTIFICATION DE LA MOTO FAHRZEUG IDENTIFIZIERUNG IDENTIFICATION DE LA MOTO Il y a deux bonnes raisons de conna tre le nu...

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

Page 31: ...korrekten Zusammen bau 5 Feuer fern halten INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMATIONS IMPORTANTES PREPARATION A LA DEPOSE ET AU DEMONTAGE 1 Eliminer soigneusement salet boue poussi r...

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: ...Nous recommandons d utiliser des pi ces Yamaha d origine pour tous les remplacements Utiliser les graisses et ou huiles recommand es par Yamaha lors des remontages et r glages JOINTS BAGUES D ETANCHEI...

Page 34: ...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 the...

Page 35: ...bliches Kontaktspray sollte nur als Notl sung verwendet werden Das Taschen Multimeter wie in der Abbil dung gezeigt anschlie en INFORMATIONS IMPORTANTES VERIFICATION DES CONNEXIONS WICHTIGE INFORMATI...

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: ...ller 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 sur face etc ACC QUICK GS...

Page 39: ...extracteur inertie Cet outils sont utilis s pour la d pose ou la repose des axes de culbuteur YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Cl pour crou de direction Cet outil sert serrer l c...

Page 40: ...184 Poids 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 Cet instrument se...

Page 41: ...t outil sert d poser le rotor YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 Cet agent d tanch it p te s utilise sur les plans de joint du carter moteur etc ACC QU...

Page 42: ...ug Anwendung Abbildung YU 1083 A 90890 01084 90890 01085 Schlagabzieher Satz Gewicht Schlagabzieher Schraube Zum Ein und Ausbau der Kipphebelwellen YU 1083 A 90890 01084 90890 01085 YU 1268 90890 0126...

Page 43: ...YM 33963 90890 01184 Gewicht des Gabeldichtring Treibers Zum Einbau des Gabeldichtrings YM 33963 90890 01184 YM 34487 90890 06754 Z ndfunkenstrecken Tester Z ndungstester Zur Pr fung des Z ndsystems...

Page 44: ...bau des Rotors YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Dichtmasse Nr 1215 Zum Abdichten von Kurbelgeh use Passfl chen und dergleichen ACC QUICK GS KT 90890 85505 Teilenu...

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

Page 46: ...an emer gency such when the machine is up set or trouble takes place in the throttle system The engine will not start or run when the engine stop switch is turned to START SWITCH TT R90E The start swi...

Page 47: ...den ersten Gang schalten FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION FONCTIONS DES COMMANDES CONTACTEUR A CLE TT R90E Les fonctions correspondant aux diff rentes posi tions du conta...

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: ...die Hinterradbremse bet tigt FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION KICK AVERTISSEMENT Avant de mettre le moteur en marche ne pas oublier de mettre au point mort D ployer le ki...

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

Page 51: ...Ausf hrung ver schiedener Wartungs und Reparaturarbeiten FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION ROBINET DE CARBURANT Le robinet de carburant am ne le carburant du r servoir au c...

Page 52: ...it may over 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 valve...

Page 53: ...Imp gal 1 11 US gal Davon Reserve 0 5 L 0 11 lmp gal 0 13 US gal CARBURANT KRAFTSTOFF CARBURANT Utiliser de l essence normale Toujours utiliser de l essence fra che d une bonne marque AVERTISSEMENT N...

Page 54: ...kstarter 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 completely close the throttle grip 5 Slide the ENGINE STOP switch...

Page 55: ...Placer le robinet de carburant en position ON 2 Placer le contacteur cl sur ON 3 Mettre au point mort 4 Tirer le starter et couper les gaz compl tement 5 Faire basculer le coupe circuit du moteur en...

Page 56: ...ellen 2 Den Z ndschl ssel auf ON stellen 3 Das Getriebe in die Leerlaufstellung schalten 4 Den Choke bet tigen und den Gasdrehgriff ganz schlie en 5 Den Motorstoppschalter ENGINE STOP auf stellen 6 De...

Page 57: ...and lubricate the chain to prevent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfaces Avoid c...

Page 58: ...rouille 7 Nettoyer la selle l aide d un produit de net toyage pour similicuir afin de conserver intacts la souplesse et le lustre de la housse 8 De la cire pour automobile peut tre utilis e pour toute...

Page 59: ...nd sofort schmieren um Korrosion zu verhindern 7 Die Sitzbank mit einem Reiniger f r Vinyl polster abwischen damit der Bezug geschmeidig und gl nzend bleibt 8 Lack und Chromfl chen k nnen mit Auto wac...

Page 60: ...in Seat height 625 mm 24 6 in Wheelbase 1 040 mm 40 9 in Minimum ground clearance 160 mm 6 3 in Dry weight Without oil and fuel TT R90 60 0 kg 132 3 lb TT R90E 63 0 kg 138 9 lb Engine Engine type Air...

Page 61: ...85 US qt Total 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 and ZA Tank capacity 4 2 L 0 92...

Page 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...0 2 7 0 7 5 1 Carburetor joint carburetor side M6 1 0 2 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...

Page 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...ur 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 sec Sans huile ni carburant TT R90 60 0 kg 132 3 lb TT R90E 63 0 kg 138 9 lb Moteur Type de moteur...

Page 78: ...L 0 70 Imp 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...

Page 79: ...arri re CHENG SHIN Type avant et arri re KNOBBY Pression de gonflage 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...

Page 80: ...imite d ovalisation 0 05 mm 0 0020 in Arbre cames M thode de transmission Transmission par cha ne gauche Dimensions de came Admission A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 034 2...

Page 81: ...in largeur de la port e B IN 1 19 2 51 mm 0 0469 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 in largeur du si ge C 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...

Page 82: ...IN 32 45 mm 1 28 in 26 9 mm 1 06 in EX 32 45 mm 1 28 in 26 9 mm 1 06 in Longueur mont soupape ferm e IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Pression la compression mont IN 138 158 N 14 07 16 11 kg 31...

Page 83: ...13 000 mm 0 5117 0 5118 in 12 980 mm 0 511 in Segments de piston 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...

Page 84: ...rmation de la tige de d brayage 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 3 800 tr mn S lecteur T...

Page 85: ...huile Type de tamis Type de pompe huile Type trocho de Jeu entre rotors 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 entre le corps et le...

Page 86: ...7 0 7 5 1 Raccord de carburateur c t carburateur M6 1 0 2 7 0 7 5 1 Bo tier de filtre air M6 1 0 2 7 0 7 5 1 Tube d chappement M6 1 0 2 7 0 7 5 1 Protection du tube d chappement M6 1 0 7 7 0 7 5 1 Si...

Page 87: ...e D battement d amortisseur 48 mm 1 89 in Longueur de ressort libre 169 mm 6 65 in Longueur mont 165 mm 6 5 in Raideur de ressort standard K 45 6 N mm 4 65 kg mm 260 lb in Ressort en option Non Pressi...

Page 88: ...110 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...

Page 89: ...u guidon inf rieur M10 1 25 2 40 4 0 29 Support du 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 2 7 0 7 5 1 Ecrou de...

Page 90: ...0 C 68 F brun vert R sistance de la bobine d excitation couleur 248 372 20 C 68 F rouge blanc Bo tier CDI mod le fabricant 4GL 20 YAMAHA Bobine d allumage Mod le fabricant 2JN 00 YAMAHA Longueur d tin...

Page 91: ...d le fabricant F5HN YAMAHA Puissance nominale 14 V 100 W 5 000 tr min R sistance de la bobine d clairage 1 couleur 0 64 0 96 20 C 68 F blanc noir R sistance de la bobine d clairage 2 couleur 0 52 0 78...

Page 92: ...ECO Amp rage 180 A R sistance de l enroulement 4 2 4 6 20 C 68 F Relais de coupe circuit de d marrage Mod le fabricant ACM33221 MATSUSHITA R sistance de l enroulement 75 69 92 51 20 C 68 F Fusibles am...

Page 93: ...ndent pour des filets propres et secs Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filet DEFINITION DES UNITES A crou B boulon SPECIFICATION DE CO...

Page 94: ...he 865 mm 34 1 in Sitzh he 625 mm 24 6 in Radstand 1 040 mm 40 9 in Bodenfreiheit 160 mm 6 3 in Trockengewicht Ohne l und Kraftstoff TT R90 60 0 kg 132 3 lb TT R90E 63 0 kg 138 9 lb Motor Bauart Luft...

Page 95: ...0 70 Imp qt 0 85 US qt Gesamtmenge 1 0 L 0 88 Imp qt 1 06 US qt Luftfilter Nassfiltereinsatz Kraftstoff Sorte Ausschlie lich bleifreies Benzin USA AUS und NZ Ausschlie lich bleifreies Normalbenzin CD...

Page 96: ...nd hinten CHENG SHIN Modell vorn und hinten KNOBBY Reifenluftdruck vorn und hinten 100 kPa 1 00 kgf cm2 14 5 psi Bremsen Vorderradbremse Trommelbremse Bet tigung Handbremshebel rechts Hinterradbremse...

Page 97: ...1 8524 in Max Ovalit t 0 05 mm 0 0020 in Nockenwelle Antriebsart Kettenantrieb links Nocken Abmessungen Einlass 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 98: ...49 3 07 mm 0 0587 0 1209 in Ventilsitz Breite C Einlass 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Auslass 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Ventilteller St rke D Einlass 0 5 0 9 mm 0 019...

Page 99: ...in 26 9 mm 1 06 in Auslass 32 45 mm 1 28 in 26 9 mm 1 06 in Einbaul nge Ventil geschlossen Einlass 24 2 mm 0 95 in Auslass 24 2 mm 0 95 in Federkraft bei Einbaul nge Einlass 138 158 N 14 07 16 11 kg...

Page 100: ...2 980 mm 0 511 in Kolbenringe 1 Kompressionsring Topring Ausf hrung Abgerundet Abmessungen B T 1 0 2 0 mm 0 04 0 08 in Ringsto in Einbaulage 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Ringnutspiel in...

Page 101: ...tangen Verbiegung 0 5 mm 0 02 in Automatische Fliehkraftkupplung Einr ckdrehzahl 2 160 2 560 U min Anfahrdrehzahl 3 300 3 800 U min Schaltung Schaltmechanismus Schaltwalze und F hrungsstange Kickstart...

Page 102: ...Bauart Trochoidenpumpe Rotor Radialspiel A oder B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Innen und Au enrotor Radialspiel 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Innen und Au enrotor Axialspiel 0...

Page 103: ...1 0 2 7 0 7 5 1 Vergasereinlass Anschluss M6 1 0 2 7 0 7 5 1 Luftfiltergeh use M6 1 0 2 7 0 7 5 1 Auspuffkr mmer M6 1 0 2 7 0 7 5 1 Auspuffkr mmer Blende M6 1 0 7 7 0 7 5 1 Schalld mpfer M8 1 25 1 24...

Page 104: ...Federweg 48 mm 1 89 in L nge der ungespannten Feder 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 D mpfergasdruck 2 000 kPa 20...

Page 105: ...37 in Vorderrad Trommelbrems Belag st rke 3 mm 0 12 in 2 mm 0 08 in Hinterrad Trommelbrems Belag st rke 4 mm 0 16 in 2 mm 0 08 in L nge der ungespannten Vorder rad Trommelbremsbelag R ckhol feder 32...

Page 106: ...8 1 25 2 20 2 0 14 Obere Gabelbr cke und Lenkerhalter unten M10 1 25 2 40 4 0 29 Lenkerhalter oben TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Vorderrad Bremszughalterung und Gabel holme M6...

Page 107: ...2 bei 20 C 68 F Braun Gr n Impulsgeber Widerstand Kabelfarbe 248 372 bei 20 C 68 F Rot Wei Z ndbox Typ Hersteller 4GL 20 YAMAHA Z ndspule Typ Hersteller 2JN 00 YAMAHA Min Z ndfunkenstrecke 6 mm 0 24 i...

Page 108: ...Typ Hersteller F5HN YAMAHA Nennleistung 14 V 100 W bei 5 000 U min Widerstand Kabelfarbe der Lichtspule 1 0 64 0 96 bei 20 C 68 F Wei Schwarz Widerstand Kabelfarbe der Lichtspule 2 0 52 0 78 bei 20 C...

Page 109: ...DECO Nennstromst rke 180 A Wicklungs Widerstand 4 2 4 6 bei 20 C 68 F Anlasssperrrelais Typ Hersteller ACM33221 MATSUSHITA Wicklungs Widerstand 75 69 92 51 bei 20 C 68 F Sicherungs St rke Anzahl Siche...

Page 110: ...ie genannten Anzugsmomente f r saubere und trockene Schraubverbindun gen bei Raumtemperatur A Schl sselweite B Gewindedurchmesser MASSEINHEITEN A Mutter B Schrau be ANZUGSMOMENT Nm m kg ft lb 10 mm 12...

Page 111: ...2 18 SPEC MEMO...

Page 112: ...ark plug lead 0 Throttle 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...

Page 113: ...en CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME CHEMINEMENT DES CABLES TT R90 1 Durit de mise l air du carter moteur 2 Faisceau de fils 3 Fil du volant magn tique CDI 4 C ble de starter 5 Fil de chau...

Page 114: ...oil 9 Cable guide 0 Wire 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...

Page 115: ...tmaschinen Kabel L Thermoschalter CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME 1 Guide c ble 2 C ble de frein 3 C ble des gaz 4 Durit de mise l air du r servoir de carburant 5 Fil du coupe circuit du...

Page 116: ...Fasten the CDI unit lead 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 a...

Page 117: ...Das Lichtmaschinen Kabel durch die F hrung leiten CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Acheminer la durit de mise l air de r servoir de car burant dans le guide c ble Acheminer le c ble des...

Page 118: ...e cable 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 brac...

Page 119: ...befestigen CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME TT R90E 1 Durit de mise l air du carter moteur 2 Fil du volant magn tique CDI 3 Faisceau de fils 4 Contacteur thermique 5 Fil du contacteur th...

Page 120: ...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 121: ...LF HRUNGSDIAGRAMME 1 Collier pince 2 Fil du coupe circuit du moteur 3 Fil du contacteur cl 4 Fil du contacteur du d marreur 5 C ble de frein 6 C ble des gaz 7 Durit de mise l air du r servoir de carbu...

Page 122: ...stic locking tie For fastening pass the plastic 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 t...

Page 123: ...GRAMME Acheminer le fil du contacteur du d marreur le fil du contacteur cl le fil du coupe circuit du moteur et le c ble des gaz par le guide c ble Acheminer la durit de mise l air de r servoir de car...

Page 124: ...e start switch lead main 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 th...

Page 125: ...EMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Attacher le c ble de starter le fil du contacteur ther mique le fil du bo tier CDI le fil du contacteur cl et le fil du coupe circuit du moteur Attacher le...

Page 126: ...t cut off relay lead does 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...

Page 127: ...ie Z ndbox Kabel wie abgebil det platzieren CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Acheminer le fil du relais de d marreur dans le relais de d marreur Placer les extr mit s du ruban blanc dans...

Page 128: ...nce Check and adjust valve clearance when engine is cold 4 Air filter element Clean with solvent Replace if necessary 5 Breather system Check ventilation hose for cracks or damage Replace if necessary...

Page 129: ...m soap based grease lightly 21 Front fork Check operation and for oil leakage Replace if necessary 22 Shock absorber assembly Check operation and for oil leakage Replace if necessary 23 Control cables...

Page 130: ...D MAINTENANCE Item Routine Page Brake Check operation adjustment P3 12 Engine oil Change oil as required P3 6 8 Drive chain Check alignment adjustment lubrication P3 13 15 Spark plug Check color condi...

Page 131: ...at R gler l cartement et nettoyer 3 Jeu aux soupapes V rifier et ajuster le jeu aux soupapes lorsque le moteur est froid 4 El ment du bo tier de filtre air Nettoyer l aide d un solvant Remplacer si n...

Page 132: ...ein Appliquer l g rement de la graisse base de savon au lithium 20 Pivot de b quille Contr ler le fonctionnement Appliquer l g rement de la graisse base de savon au lithium 21 Fourche Contr ler le fon...

Page 133: ...ement et le r glage P3 12 Huile moteur Changer l huile comme sp cifi P3 6 8 Cha ne de transmission Contr ler l alignement le r glage et la lubrification P3 13 15 Bougie Contr ler la couleur et l tat P...

Page 134: ...n 2 Z ndkerze Zustand pr fen Elektrodenabstand einstellen und reinigen 3 Ventilspiel Das Ventilspiel bei kaltem Motor kontrollieren und einstellen 4 Luftfiltereinsatz Mit L sungsmittel s ubern Gegeben...

Page 135: ...bestreichen 20 Seitenst nder Drehpunkt Funktion kontrollieren Leicht mit Lithiumseifenfett bestreichen 21 Teleskopgabel Funktion pr fen und auf Undichtigkeit untersuchen Gegebenenfalls erneuern 22 Fed...

Page 136: ...ollpunkt Ausf hrung Seite Bremsen Funktion und Einstellung kontrollieren S 3 12 Motor l Gegebenenfalls wechseln S 3 6 8 Antriebskette Ausrichtung Spannung und Schmierzustand kontrollieren S 3 13 15 Z...

Page 137: ...INSP ADJ MEMO...

Page 138: ...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 139: ...ISSEMENT Apr s le r glage tourner le guidon vers la droite et vers la gauche et contr ler que le r gime de ralenti du moteur ne change pas 3 4 MOTOR GASZUG EINSTELLEN 1 Kontrollieren Gaszugspiel a am...

Page 140: ...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 141: ...filtre air et les trous b de l l ment du bo tier de filtre air 7 Monter Couvercle du bo tier de filtre air 8 Monter Prise d air droite 3 5 1 Montieren Lufthutze rechts 1 2 Montieren Luftfilter Geh use...

Page 142: ...ow Add oil 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...

Page 143: ...huile moteur SAE 10W 30 de type SE SF SG A 5 C 40 F ou plus Yamalube 4 20W 40 ou huile moteur SAE 20W 40 de type SE SF SG 3 6 MOTOR LSTAND KONTROLLIEREN 1 Den Motor anlassen einige Minuten lang warm...

Page 144: ...E Wait a few minutes until the oil settles before inspecting the oil level Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommend...

Page 145: ...n des diff rentes temp ratures atmos ph riques Classification des huiles moteur recommand es NORME API API SE SF SG ou qualit sup rieure destin e essentiellement aux motos 3 7 Nicht USA und CDN ACHTUN...

Page 146: ...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 147: ...mais sans forcer D visser du nombre de tours sp cifi s Vis d air de ralenti D visser de 1 3 4 tour 3 8 5 Montieren Dichtung Ablassschraube New T R 20 Nm 2 0 m kg 14 ft lb 6 Bef llen Kurbelgeh use lle...

Page 148: ...eck 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 149: ...s gaz 1 dans le sens a Pour diminuer le r gime de ralenti Tour ner la vis de but e de papillon des gaz 1 dans le sens b Compte tours inductif YU 8036 B 90890 03113 R gime de ralenti 1 400 1 600 tr mn...

Page 150: ...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 151: ...soupapes Si le jeu est incorrect r p ter les tapes ci des sus jusqu obtention du jeu sp cifi T R 7 Nm 0 7 m kg 5 1 ft lb 3 10 4 Kontrollieren Ventilspiel Nicht nach Vorgabe Korrigieren 5 Einstellen V...

Page 152: ...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 de...

Page 153: ...ent et aligner le trou du boulon Boulon tuyau d chappement arri re T R 18 Nm 1 8 m kg 13 ft lb New T R 18 Nm 1 8 m kg 13 ft lb New T R 13 Nm 1 3 m kg 9 4 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7...

Page 154: ...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 155: ...age 1 jusqu obtention du jeu sp cifi Visser Le jeu diminue D visser Le jeu augmente ATTENTION Apr s le r glage contr ler que le frein ne frotte pas 3 12 FAHRWERK VORDERRADBREMSE EINSTELLEN 1 Kontrolli...

Page 156: ...ve chain 2 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain 3 Measure Drive chain length 15 links a Out of spec...

Page 157: ...ONTR LE DES PIGNONS CONTR LE DE LA CHA NE DE TRANSMISSION KETTENR DER KONTROLLIEREN ANTRIEBSKETTE KONTROLLIEREN CONTR LE DES PIGNONS 1 Contr ler Dent de pignon a Usure excessive Changer N B Changer le...

Page 158: ...nts DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Check Drive chain slack a In the center between the drive axle and rear wheel axle Out of sp...

Page 159: ...LA CHAINE DE TRANSMISSION ANTRIEBSKETTEN DURCHHANG EINSTELLEN 5 Monter Cha ne de transmission 1 Maillon d tachable 2 Agrafe de maillon d tachable 3 ATTENTION Bien veiller reposer l agrafe de maillon...

Page 160: ...s a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear CAUTION Too small chain slack will overload the engine and othe...

Page 161: ...n douceur de la fourche avant Actionner le frein avant et enfoncer la four che Fonctionnement dur fuite d huile R parer ou remplacer 3 15 3 Einstellen Antriebsketten Durchhang Antriebsketten Durchhang...

Page 162: ...levate the rear wheel by placing the suit able stand under the engine 2 Remove Rear shock absorber Refer to SWINGARM section in the CHAPTER 5 3 Remove Spring guide 1 NOTE While compressing the spring...

Page 163: ...la pr contrainte du ressort monter le circlip dans la rainure b N B Ne pas trop carter le circlip Position de montage standard Rainure b 5 Monter Guide de ressort 1 N B Monter le guide du ressort en...

Page 164: ...tes that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100...

Page 165: ...ler retendre ces rayons avant et apr s le rodage Apr s un entra nement ou une course con tr ler le serrage des rayons T R 2 Nm 0 2 m kg 1 4 ft lb 3 17 6 Montieren Federbein Siehe unter SCHWINGE in KAP...

Page 166: ...ront wheel by placing a suit able stand under the engine 2 Check Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check St...

Page 167: ...ection Etapes de r glage de l crou de direction D poser le garde boue avant 1 D poser le guidon et le t sup rieur Desserrer l crou de direction 2 l aide de la cl pour crou de direction 3 3 18 R DER KO...

Page 168: ...the ring nut using the ring nut wrench WARNING Avoid over tightening T R Ring nut final tightening 1 Nm 0 1 m kg 0 7 ft lb Check the steering shaft by turning it lock to lock If there is any binding r...

Page 169: ...ni re que les espaces b soient gaux T R Boulon de colonne de direction 40 Nm 4 0 m kg 2 9 ft lb Bouchon de tube de fourche 40 Nm 4 0 m kg 2 9 ft lb Support de guidon sup rieur 13 Nm 1 3 m kg 9 4 ft lb...

Page 170: ...wrench so that they form a right angle Ring nut wrench YM 33975 90890 01403 T R Ring nut initial tightening 38 Nm 3 8 m kg 27 ft lb Loosen the ring nut one turn Retighten the ring nut using the ring...

Page 171: ...ournant d une but e l autre S il y a la moindre g ne d monter l arbre de direction complet et con tr ler les paliers de la direction Reposer le t sup rieur 6 le commutateur cl 7 le guidon 8 et le gard...

Page 172: ...handlebar holder should be installed with the punched mark b for ward CAUTION First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side T R Steerin...

Page 173: ...tion 40 Nm 4 0 m kg 2 9 ft lb Bouchon de tube de fourche 40 Nm 4 0 m kg 2 9 ft lb Support de guidon sup rieur 23 Nm 2 3 m kg 17 ft lb 3 21 HINWEIS Die Lenker Halterung so montieren dass deren Kerbe a...

Page 174: ...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 175: ...les ou d un produit quivalent Utiliser de l huile moteur SAE 10W 30 ou un lubri fiant pour cha nes ad quat Lubrifier les points suivants l aide de graisse fluide base de savon de lithium de haute qual...

Page 176: ...s 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 Cle...

Page 177: ...ter une bougie nettoyer le plan de joint et la surface de la bougie Serrer la bougie la main a avant de la serrer au couple correct b T R 13 Nm 1 3 m kg 9 4 ft lb 3 23 ELEKTRISCHE ANLAGE Z NDKERZE KON...

Page 178: ...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 179: ...rm ment la m thode de charge illustr e dans ce manuel Si l on surcharge la batterie son niveau d lectro lyte diminuera consid rablement Il convient donc de charger la batterie avec beaucoup de prudenc...

Page 180: ...ead 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 181: ...mesurant la tension entre ses bornes en circuit ouvert c est dire la ten son apr s d connexion de la borne positive Inutile de recharger tant que la tension en cir cuit ouvert est sup rieure ou gale 1...

Page 182: ...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 183: ...t tre char g e sur la moto d connecter le c ble n gatif de la borne de la batterie Afin de r duire le risque de production d tin celles ne pas brancher le chargeur de batterie avant d avoir connect le...

Page 184: ...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 185: ...en se stabilise environ 30 minutes apr s la fin de la charge Par cons quent attendre 30 minutes apr s la charge avant de mesurer la tension en circuit ouvert 3 27 Ebenso die Anschlussklemmen des Lade...

Page 186: ...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 187: ...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 188: ...e charge standard est il d pass NON OUI Si le courant ne d passe pas le courant de charge standard apr s 5 minutes remplacer la batterie Si le temps de charge requis d passe 5 heures il est conseill d...

Page 189: ...atterie pendant plus de 30 minutes avant de mesurer sa tension en circuit ouvert 12 8 V La charge est termin e 12 0 12 7 V Une nouvelle charge est n cessaire Moins de 12 0 V Remplacer la batterie Ce t...

Page 190: ...omst rke berschritten NEIN JA bersteigt die Amperezahl nach f nf Minuten nicht die normale Ladestromst rke muss die Batterie ersetzt werden bersteigt die ben tigte Ladezeit f nf Stunden ist es ratsam...

Page 191: ...essen der Ruhespannung die Batterie mindestens 30 Minuten lang nicht benutzen 12 8 V Der Ladevorgang ist abge schlossen 12 0 12 7 V Weiteres Laden ist erfor derlich Unter 12 0 V Die Batterie erneuern...

Page 192: ...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 193: ...ircuit N B R gler le s lecteur du multim tre sur 1 Multim tre YU 03112 C 90890 03112 Si le multim tre indique remplacer le fusible 3 30 6 Montieren Batterie 7 Kontrollieren Batteriepole Verschmutzt Mi...

Page 194: ...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 195: ...onctionne Si le fusible grille nouveau imm diatement contr ler le circuit lectrique El ments Amp rage Q t Fusible principal 10 A 1 3 31 3 Erneuern durchgebrannte Sicherung WARNUNG Eine Sicherung niema...

Page 196: ...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 197: ...zst ck 1 9 Vergaserdeckel 1 10 Chokeschieber 1 1 CARBURATEUR VERGASER MOTEUR CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre Nom de la pi ce Q t Remarques...

Page 198: ...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 199: ...hokeschieber 1 9 Chokezug 1 0 Schwimmerkammer 1 1 CARBURATEUR VERGASER DEMONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de la pi ce Q t...

Page 200: ...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 201: ...ube 1 H Leerlaufgemisch Regulier schraube 1 I Vergaserheizung 1 1 CARBURATEUR VERGASER Organisation de la d pose Ordre Nom de la pi ce Q t Remarques A Axe de flotteur 1 B Flotteur 1 C Pointeau 1 D Gic...

Page 202: ...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 203: ...NWEIS Den Gasschieber 1 in das Vergasergeh use einsetzen und dessen Leichtg ngigkeit kon trollieren CARBURATEUR VERGASER CONTROLE Carburateur 1 Contr ler Corps du carburateur Encrass Nettoyer N B Nett...

Page 204: ...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 resulting in an incorrect measurement Measure the dist...

Page 205: ...sind den Schwimmerstand durch leichtes Biegen der Lasche 1 ein stellen Den Schwimmerstand erneut kontrollie ren CARBURATEUR VERGASER Aiguille 1 Contr ler Aiguille 1 D formation usure Remplacer Rainur...

Page 206: ...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 207: ...e sind leicht ent flammbar und explosiv Deshalb Funken offene Flammen brennende Zigaretten und andere Feuerquellen fernhalten CARBURATEUR VERGASER Flotteur 1 Contr ler Flotteur 1 Endommagement Remplac...

Page 208: ...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 209: ...A 90890 01312 Kraftstoffstand 2 3 mm 0 08 0 12 in unterhalb der Schwimmerkammer Markierung CARBURATEUR VERGASER 1 Mesurer Niveau de carburant a Utiliser une jauge de niveau de carburant 1 Hors sp cifi...

Page 210: ...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 211: ...NZELHEITEN 8 Steuerkettenspanner 1 9 Dichtung 1 1 CULASSE ZYLINDERKOPF CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de la pi ce Q t Remarques DEPOSE DE...

Page 212: ...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 213: ...DEMON TAGE EINZELHEITEN 11 Steuerkette 1 12 Zylinderkopf 1 13 Dichtung 1 14 Passh lse 2 1 CULASSE ZYLINDERKOPF Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 10 Pignon d arbre cames 1 S...

Page 214: ...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 215: ...urbelgeh use hinab f llt Beim Demontieren der Schraube 1 die Rotor Mutter mit einem Schraubenschl ssel gegenhalten CULASSE ZYLINDERKOPF POINTS DE DEPOSE Culasse 1 Aligner Rep re I avec index fixe Etap...

Page 216: ...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 217: ...ge des Nockenwellenrads darauf achten dass die Steuerkette an der Auslassseite m glichst straff ist CULASSE ZYLINDERKOPF 4 D poser Culasse N B Desserrer les boulons et crous dans l ordre de desserrage...

Page 218: ...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 219: ...rschrifts m ig festziehen T R Verschlussschraube 8 Nm 0 8 m kg 5 8 ft lb CULASSE ZYLINDERKOPF ATTENTION Veiller ce que le vilebrequin reste immobile pendant la repose de l arbre cames Cela risquerait...

Page 220: ...name 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...

Page 221: ...ntilspiel Einstellschraube 2 7 Ventilspiel Einstellschraube 2 2 1 ARBRE A CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL ARBRE A CAMES ET CULBUTEURS Organisation de la d pose 1 D pose du culbuteur 2 D...

Page 222: ...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 223: ...r l auf das Nockenwellenlager 2 Montieren Nockenwelle 1 ARBRE A CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL POINTS DE DEPOSE Axe de culbuteur 1 D poser Axes de culbuteur N B Utiliser un extracteur i...

Page 224: ...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 225: ...ipphebel und Kipphebelwelle 4 Montieren Kipphebel 1 Kipphebelwelle 2 ARBRE A CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL 3 Appliquer Huile au bisulfure de molybd ne sur le culbuteur et l axe de culb...

Page 226: ...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 227: ...1 5 Auslassventil 1 6 Ventilschaft Dichtring 2 1 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la d pose 1 D pose des soupapes Organisation d...

Page 228: ...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 229: ...Erneuern Max Schlag 0 02 mm 0 0008 in SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN POINTS DE DEPOSE D pose des soupapes 1 D poser Clavettes de soupape 1 N B Fixer un compresseur de ressor...

Page 230: ...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 231: ...uss der Ventilsitz nachbearbeitet werden SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN Ressort de soupape 1 Mesurer Longueur libre du ressort de soupape a Hors sp cifications Remplacer 2 Me...

Page 232: ...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 233: ...er Vorgabe entspricht Ventilkegel und sitz erneut einschleifen SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN 2 Roder Port e de soupape Si ge de soupape N B Apr s rectification du si ge de s...

Page 234: ...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 235: ...n SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN ASSEMBLAGE ET MONTAGE 1 Appliquer Huile au bisulfure de molybd ne sur la queue de soupape et le joint de queue de soupape 2 Monter Joints de...

Page 236: ...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 237: ...TAGE EINZELHEITEN 9 2 Kolbenring 1 10 labstreifring Expander 2 1 2 1 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Organis...

Page 238: ...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 239: ...messen Anschlie end den Durchschnitt der gemessenen Werte ermitteln CYLINDRE ET PISTON ZYLINDER UND KOLBEN POINTS DE DEPOSE Piston 1 D poser Clips d axes de pistons 1 Axe de piston 2 Piston 3 N B Avan...

Page 240: ...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 241: ...olbenringe erneuern CYLINDRE ET PISTON ZYLINDER UND KOLBEN Al sage de cylindre C 47 000 47 005 mm 1 8504 1 8506 in Limite de conicit T 0 05 mm 0 002 in Ovalisation R 0 05 mm 0 002 in C maximum D T max...

Page 242: ...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 243: ...fring 0 2 0 7 mm 0 01 0 03 in CYLINDRE ET PISTON ZYLINDER UND KOLBEN Segment de piston 1 Mesurer Jeu lat ral du segment Utiliser une jauge d paisseur lames Hors sp cifications Remplacer ensemble le pi...

Page 244: ...ngs 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 outs...

Page 245: ...zwert 13 045 mm 0 5136 in CYLINDRE ET PISTON ZYLINDER UND KOLBEN Axe de piston 1 Contr ler Axe de piston D coloration bleue rainures Remplacer puis contr ler le syst me de lubri fication 2 Mesurer Dia...

Page 246: ...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 247: ...schiene nicht besch digt wird Die Steuerkette durch den Steuerketten schacht f hren New CYLINDRE ET PISTON ZYLINDER UND KOLBEN 2 Position Segment de feu Segment d tanch it Segment racleur d huile D c...

Page 248: ...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 249: ...starterhebel 1 8 Kurbelgeh usedeckel rechts 1 9 Dichtung 1 10 Passh lse 2 2 1 EMBRAYAGE KUPPLUNG EMBRAYAGE COUVERCLE DE CARTER GAUCHE ET DROIT Organisation de la d pose 1 D pose du couvercle de carter...

Page 250: ...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 251: ...0 Kupplungsnabe 1 11 Beilagscheibe 1 12 Kupplungskorb 1 2 1 3 EMBRAYAGE KUPPLUNG EMBRAYAGE Organisation de la d pose 1 D pose du disque garni et du plateau de pression 2 D pose de la cloche d embrayag...

Page 252: ...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 253: ...Anfahrkupplungsnabe 1 20 Antriebstr ger 1 21 Freilauf 1 22 Beilagscheibe 1 3 2 EMBRAYAGE KUPPLUNG Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 13 Entretoise 1 14 Entretoise 1 15 Ecro...

Page 254: ...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 255: ...rke Standard Grenzwert 2 7 2 9 mm 0 106 0 114 in 2 6 mm 0 102 in EMBRAYAGE KUPPLUNG POINTS DE DEPOSE Noix d embrayage 1 D poser Ecrou de noix d embrayage 1 Rondelle frein 2 Noix d embrayage N B Redre...

Page 256: ...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 257: ...4 in EMBRAYAGE KUPPLUNG Plateau de pression 1 Mesurer D formation du plateau de pression Hors sp cifications Remplacer le plateau de pression complet Utiliser une plaque surfacer 1 et une jauge d pais...

Page 258: ...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 259: ...n Um 1 8 Umdrehung herausdrehen Die Sicherungsmutter festziehen T R Sicherungsmutter 8 Nm 0 8 m kg 5 8 ft lb EMBRAYAGE KUPPLUNG ASSEMBLAGE ET MONTAGE Embrayage primaire 1 Monter Rondelle 1 Ecrou embra...

Page 260: ...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 261: ...ng 1 10 Beilagscheibe Federscheibe 1 1 11 Kickstarter Ritzel 1 12 Kickhebelwelle 1 2 1 ARBRE DE KICK KICKHEBELWELLE ARBRE DE KICK Organisation de la d pose 1 D pose de l arbre de kick 2 D montage de l...

Page 262: ...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 263: ...haltklinke komplett 1 13 Schaltwelle 1 1 AXE DE SELECTEUR SCHALTWELLE AXE DE SELECTEUR Organisation de la d pose 1 D pose de l axe de s lecteur Organisation de la d pose Ordre Nom de la pi ce Q t Rema...

Page 264: ...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 265: ...cherungsring 1 17 Unterlegscheibe 1 18 Torsionsfeder 1 19 Schaltklinke 1 1 AXE DE SELECTEUR SCHALTWELLE Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 14 Doigt de verrouillage 1 15 Ress...

Page 266: ...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 267: ...9 Sicherungsring 1 10 Beilagscheibe 1 2 1 3 POMPE A HUILE LPUMPE 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 Organisat...

Page 268: ...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 269: ...lle 1 14 Stift 1 15 Innenrotor 1 16 Au enrotor 1 17 Rotorgeh use 1 3 POMPE A HUILE LPUMPE Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 11 Couvercle de pompe huile 1 12 Goujon 2 13 Arb...

Page 270: ...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 271: ...ung b in der Kur belwelle ausrichten POMPE A HUILE LPUMPE CONTROLE Pompe huile 1 Mesurer Jeu entre rotors a entre le rotor interne 1 et le rotor externe 2 Jeu lat ral b entre le rotor externe 2 et le...

Page 272: ...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 273: ...EITEN 4 Rotor 1 5 Scheibenfeder 1 2 1 VOLANT MAGNETIQUE CDI TT R90 LICHTMASCHINE TT R90 VOLANT MAGNETIQUE CDI TT R90 Organisation de la d pose 1 D pose de l ensemble bobine d excitation stator 2 D pos...

Page 274: ...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 275: ...tzen Polrad Abzieher YU 33270 B 90890 01362 VOLANT MAGNETIQUE CDI TT R90 LICHTMASCHINE TT R90 POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Rondelle 2 N B Desserrer l crou de rotor tout en immobil...

Page 276: ...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 277: ...OLANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E VOLANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E Organisation de la d pose 1 D pose de l ensembl...

Page 278: ...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 279: ...33270 B 90890 01362 VOLANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Rondelle 2 N B Desserrer l crou...

Page 280: ...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 281: ...UE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E CONTROLE Embrayage du d marreur 1 Contr ler Dents du pignon fou du d marreur a Dents du pignon d entra nement du d ma...

Page 282: ...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 283: ...LANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E 3 Monter Ressort 1 Capuchon de ressort 2 Goupille 3 4 Monter Cale 1 Engrenage roue du d marreur 2 Pignon...

Page 284: ...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 285: ...khebelwelle komplett Siehe dazu den Abschnitt KICKHEBEL WELLE CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE CARTER MOTEUR ET VILEBREQUIN Organisation de la d pose Ordre Nom de la pi ce Q...

Page 286: ...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 287: ...h useteil links 1 2 1 3 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Organisation de la d pose 1 D pose de la cha ne de distribution 2 S paration du carter 3 D pose du vilebrequin Organi...

Page 288: ...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 INSTALLATI...

Page 289: ...et ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE CONTROLE Vilebrequin 1 Mesurer Limite de faux rond a Jeu lat ral de t te de bielle b...

Page 290: ...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 291: ...ibe 1 2 1 FOURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES SCHALTGABELN SCHALTWALZE UND GETRIEBE FOURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES Organisation de la d pose 1 D pose des fourche...

Page 292: ...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 293: ...ibe 1 19 Zahnrad 2 Gang 1 20 Ausgangswelle 1 3 2 FOURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES SCHALTGABELN SCHALTWALZE UND GETRIEBE Organisation de la d pose Ordre Nom de la pi ce Q t Remarque...

Page 294: ...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 295: ...OURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES SCHALTGABELN SCHALTWALZE UND GETRIEBE POINTS DE DEPOSE Fourchette de s lection tambour et bo te de vitesses 1 D poser Fourchettes de s lection Tambo...

Page 296: ...HEEL 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 1 Bolt brake cable ho...

Page 297: ...aul e 1 7 Flasque de frein complet 1 8 Bague d tanch it 1 9 Roulement 2 Se reporter la section POINTS DE DEPOSE 2 1 3 3 FAHRWERK VORDER UND HINTERRAD VORDER UND HINTERRADBREMSE Arbeitsumfang 1 Vorderr...

Page 298: ...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 299: ...pi ce Q t Remarques 10 M choire de frein 2 11 Biellette de frein 1 12 Came de frein 1 3 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 10 Trommelbremsbelag 2 11 Bremswellenhebel 1 12 Bremswelle 1...

Page 300: ...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 301: ...arri re 1 7 Tendeur de cha ne de transmission 2 8 Roue arri re 1 9 Entretoise paul e droite 1 10 Flasque de frein complet 1 2 1 3 HINTERRAD UND HINTERRADBREMSE Arbeitsumfang 1 Hinterrad demontieren 2...

Page 302: ...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 303: ...ection POINTS DE DEPOSE 14 M choire de frein 2 15 Biellette de frein 1 16 Came de frein 1 2 3 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 11 Distanzh lse links 1 12 Mitnehmernabe komplett 1 13...

Page 304: ...ake lining 1 Inspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper NOTE After polishing wipe the polished particles with a cloth Wheel runout limit Radial 1 2 0 mm 0 08 in Latera...

Page 305: ...e de m choire de frein a Standard Avant 3 0 mm 0 12 in Arri re 4 0 mm 0 16 in Limite 2 0 mm 0 08 in DEMONTAGE EINZELHEITEN Radlager nach Bedarf 1 Demontieren Lager 1 HINWEIS Das Lager mit einem Lagera...

Page 306: ...ke camshaft lever in relation to the punch mark a as shown Front Rear 1 1 a a 1 1 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Springs 1 Brake shoes 2 NOTE Apply the lithium soap base grease on the pivot pi...

Page 307: ...Hebelachse auftragen WARNUNG Niemals Fett auf die Bremsbel ge auftra gen New ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD REMONTAGE ET INSTALLATION 1 Monter Biellette de frein 1 N B Installer le l...

Page 308: ...side of wheel bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not strike the inner race of the bearing Contact should be made on...

Page 309: ...T ROUE ARRIERE VORDER UND HINTERRAD Roue avant 1 Monter Roulement de roue 1 Entretoise 2 Roulement de roue 3 Bague d tanch it 4 N B Enduire le roulement de roue et la l vre de la bague d tanch it de g...

Page 310: ...ENT section in the CHAPTER 3 Wheel drive hub assembly 1 Install Bearing 1 Oil seal 2 Collar 3 Sprocket shaft 4 Driven sprocket 5 Lock washers 6 Nuts 7 Bolts 8 NOTE Install the oil seal with its manufa...

Page 311: ...nach oben biegen New New T R 25 Nm 2 5 m kg 18 ft lb ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD 5 Monter Bride de fil de c ble de frein 1 T R 7 Nm 0 7 m kg 5 1 ft lb 6 R gler Garde du levier de...

Page 312: ...race of the bearing Right side of bearing shall be installed first CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Drive chain 1 NOTE Push...

Page 313: ...6 m kg 19 ft lb New ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD Roue arri re 1 Monter Roulement de roue 1 Entretoise 2 Roulement de roue 3 N B Avant de monter le roulement et la bague d tan ch it...

Page 314: ...ne 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 Han...

Page 315: ...e r glage 1 Desserrer uniquement 4 Boulon de pincement t inf rieur 1 Desserrer uniquement 5 Fourche 1 1 TELESKOPGABEL Arbeitsumfang 1 Teleskopgabel demontieren Arbeitsumfang Reihen folge Bauteil Anz B...

Page 316: ...oval 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 ro...

Page 317: ...outil sp cial Se reporter la section POINTS DE DEPOSE 6 Tube plongeur 1 7 Tige d amortissement 1 8 Bague d tanch it 1 9 Fourreau 1 2 1 TELESKOPGABEL ZERLEGEN Arbeitsumfang 1 Dichtring demontieren 2 D...

Page 318: ...55000 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...

Page 319: ...0 01184 Accessoire de l outil de montage de joint de fourche 90890 01186 Quantit d huile 64 cm3 2 26 Imp oz 2 16 US oz Huile recommand e Huile de fourche 15W ou quivalente DEMONTAGE EINZELHEITEN Stand...

Page 320: ...AL 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 side 7 Grip right 1 Ref...

Page 321: ...reporter la section POINTS DE DEPOSE 10 Support du guidon sup rieur 2 11 Guidon 1 12 Support du guidon inf rieur 2 1 LENKER TT R90 Arbeitsumfang 1 Lenker demontieren Arbeitsumfang Reihen folge Bautei...

Page 322: ...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 throttle side 9 Grip right...

Page 323: ...1 Se reporter la section POINTS DE DEPOSE 12 Support du guidon sup rieur 2 13 Guidon 1 14 Support du guidon inf rieur 2 1 TT R90E Arbeitsumfang 1 Lenker demontieren Arbeitsumfang Reihen folge Bauteil...

Page 324: ...come loose INSPECTION Handlebar 1 Inspect Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar ASSEMBLY AND INSTA...

Page 325: ...Klebemittels Fett oder l mit Verd nner von der Oberfl che a des Drehgriffs entfernen GUIDON LENKER POINTS DE DEPOSE Poign e de guidon 1 D poser Poign e de guidon 1 N B Insuffler de l air entre le guid...

Page 326: ...arrow marks faces straight upward 3 Install Grip right 1 Collar 2 Apply the adhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface a with a la...

Page 327: ...n kon trollieren dass sich der Gasdrehgriff 1 rei bungslos dreht Falls dies nicht der Fall ist die Schrauben nochmals festziehen GUIDON LENKER 2 Monter Poign e gauche 1 Appliquer un agent adh sif sur...

Page 328: ...grease on the front brake cable end The brake lever holder should be installed according to the dimensions as shown TT R90 TT R90E 1 2 LS 5mm 0 2 in LS Zero mm Zero in 1 2 6 Install Engine stop switc...

Page 329: ...r 1 HINWEIS Die Nase a an der Motorstoppschalter Halte rung auf die Bohrung b im Lenker ausrichten GUIDON LENKER 5 Monter Support de levier de frein 1 C ble de frein 2 N B Appliquer de la graisse savo...

Page 330: ...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 331: ...7 Billes du roulement sup rieur 19 8 Billes du roulement inf rieur 16 9 Joint antipoussi re 1 10 Cage externe de roulement 2 2 1 LENKUNG Arbeitsumfang 1 Untere Gabelbr cke demontieren 2 Lager demonti...

Page 332: ...he steering shaft so that it may not fall down Steering nut wrench YU 33975 90890 01403 Bearing race 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer EC563300 Bearing lo...

Page 333: ...l 2 benutzen ACHTUNG Darauf achten das Lenkwellengewinde nicht zu besch digen DIRECTION LENKUNG PI CES D POSER crou cr nel 1 D poser crou cr nel 1 Utiliser la cl pour crou de direction 2 AVERTISSEMENT...

Page 334: ...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 335: ...tenir le bras oscillant 5 Bras oscillant 1 6 Patin de cha ne de transmission 1 7 Protection de cha ne de transmission 1 8 Support de cha ne de transmission 1 2 1 SCHWINGE Arbeitsumfang 1 Schwinge demo...

Page 336: ...5 21 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 337: ...Remarques 9 Goupille fendue 1 10 Ecrou barre de tension 1 11 Boulon barre de tension 1 12 Barre de tension 1 1 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 9 Splint 1 10 Zugstangen Mutter 1 11 Z...

Page 338: ...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 339: ...L Wei Blau W R Wei Rot SCHALTPLAN COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE TT R90 COMPOSANTS ELECTR...

Page 340: ...ting 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 W B B B R W Br B...

Page 341: ...b Rot SCHALTPLAN COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN TT R90E COMPOSANTS ELECTRIQUES 1 Contacteur cl 2 Coupe circuit du moteur 3 Contacteur thermique 4 Bobin...

Page 342: ...ng special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark plug Check entire ignition syst...

Page 343: ...Testeur d allumage 90890 06754 Multim tre YU 3112 C 90890 03112 Test de la longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions de l ensemble du syst me d allu mage R parer ou...

Page 344: ...l lieren Z ndkerze reinigen ggf erneuern Kabelanschl sse des gesamten Z ndsystems kontrollieren Instand setzen ggf erneuern Z ndschloss kontrollieren Nur TT R90E Erneuern Motorstoppschalter ENGINE STO...

Page 345: ...ELEC MEMO...

Page 346: ...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 347: ...R 1 Br 2 B W 3 B 4 Messger t Wahlschalter ON 1 OFF SYSTEME D ALLUMAGE Z NDSYSTEM TEST DE LA LONGUEUR D ETINCELLE 1 D connecter le capuchon de bougie de la bou gie 2 Connecter le testeur d tincelle dyn...

Page 348: ...002 IGNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace 2 Inspect Secondary coil resistance Out of specification Replace NOTE When inspecting the secondary coil res...

Page 349: ...er 6 3 9 5 k bei 20 C 68 F k 1 SYSTEME D ALLUMAGE Z NDSYSTEM CONTROLE DU COUPE CIRCUIT DU MOTEUR 1 Contr ler Continuit du coupe circuit du moteur Pas de continuit la position Remplacer Continuit la po...

Page 350: ...Tester lead Red lead 1 Tester lead White lead 2 Pickup coil resistance Tester selector position 248 372 at 20 C 68 F 100 2 Inspect Source coil resistance Out of specification Replace Tester lead Brow...

Page 351: ...20 C 68 F 100 SYSTEME D ALLUMAGE Z NDSYSTEM CONTROLE DU VOLANT MAGNETIQUE CDI 1 Contr ler R sistance de la bobine d excitation Hors sp cifications Remplacer Fil du multim tre fil rouge 1 Fil du multim...

Page 352: ...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 353: ...RAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E FONCTIONNEMENT DU SYSTEME DE COUPE CIRCUIT DE DEMARRAGE Si le contacteur cl est plac sur ON le d mar reur ne peut fo...

Page 354: ...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 355: ...outils sp ciaux suivants pendant ce contr le Multim tre YU 3112 C 90890 03112 1 Contr ler le fusible Remplacer le fusible et contr ler le faisceau de fils 2 Contr ler la batterie Recharger ou remplace...

Page 356: ...ung kontrollieren Sicherung erneuern und Kabelbaum kon trollieren 2 Batterie kontrollieren Laden ggf erneuern S mtliche Steckverbinder und Kabelanschl sse kontrollieren Instand setzen ggf erneuern 3 Z...

Page 357: ...ELEC MEMO...

Page 358: ...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 359: ...atterie angeschlos sen SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS 1 Contr ler Connexion des fiches rapides et des fils Rouille p...

Page 360: ...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 361: ...er LEERLAUF 1 GANG EIN GELEGT SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE DU RELAIS DE DEMARREUR 1 D poser Relais de d marreur 2 Contr ler Continuit du relais de d marreur Uti...

Page 362: ...Start switch continuity Not 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 FR...

Page 363: ...2 Messger t Wahlschalter EINDR CKEN 1 FREI GEBEN SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE DU CONTACTEUR DU DEMARREUR 1 Contr ler Continuit du contacteur du d marreur Pas de...

Page 364: ...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 365: ...Ring 1 3 Kohleb rsten Satz 1 4 Anker 1 5 Stator 1 1 SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E DEMARREUR Organisation de la d pose 1 D montage du d marreur Organisation de la d pose...

Page 366: ...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 commu tator and insulation Out of specification Repla...

Page 367: ...68 F Entspricht einer der Widerst nde nicht der Vorgabe den Startermotor erneuern SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE ET REPARATION 1 Contr ler Collecteur Salet Nettoy...

Page 368: ...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 369: ...er auftragen Die Markierungen an Polgeh use und Lager schild m ssen fluchten SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E 5 Mesurer Longueur des balais a Hors sp cifications Remplacer L...

Page 370: ...g 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 371: ...iliser l outil sp cial suivant pour effectuer ce contr le Multim tre YU 3112 C 90890 03112 Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 1 Contr ler le fusible Remplacer le fusible e...

Page 372: ...e Taschen Multimeter YU 3112 C 90890 03112 Induktions Drehzahlmesser YU 8036 B Diagnose Drehzahlmesser 90890 03113 1 Sicherung kontrollieren Sicherung erneuern und Kabelbaum kon trollieren 2 Batterie...

Page 373: ...ELEC MEMO...

Page 374: ...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 375: ...1 SYSTEME DE CHARGE TT R90E LADESYSTEM TT R90E CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS 1 Contr ler Connexion des fiches rapides et des fils Rouille poussi re jeu court circuit R parer o...

Page 376: ...e the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Check entire carburetor heating system for connec tion...

Page 377: ...1 Selle 2 R servoir de carburant Utiliser les outils sp ciaux suivants pendant ce contr le Multim tre YU 3112 C 90890 03112 Contr ler les connexions de l ensemble du syst me de r chauffage du carburat...

Page 378: ...e verwenden Taschen Multimeter YU 3112 C 90890 03112 Kabelanschl sse der gesamten Vergaserheizan alge kontrollieren Instand setzen ggf erneuern Starterschalter kontrollieren Erneuern Vergaser Heizelem...

Page 379: ...ELEC MEMO...

Page 380: ...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 381: ...n Temperaturen auf Durchgang pr fen TT R90 TT R90E SYSTEME DE RECHAUFFAGE DU CARBURATEUR VERGASERHEIZUNG CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS 1 Contr ler Connexion des fiches rapides...

Page 382: ...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 383: ...Thermoschalters kontrol lieren SYSTEME DE RECHAUFFAGE DU CARBURATEUR VERGASERHEIZUNG Le circuit du contacteur thermique est ouvert Le circuit du contacteur thermique est ferm Etape du test Temp rature...

Page 384: ...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 385: ...52 0 78 bei 20 C 68 F 1 SYSTEME DE RECHAUFFAGE DU CARBURATEUR VERGASERHEIZUNG CONTROLE DU RECHAUFFEUR DE CARBURATEUR 1 Contr ler R sistance du r chauffeur de carburateur Hors sp cifications Remplacer...

Page 386: ...dance 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 O...

Page 387: ...li s la 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 r alis PR...

Page 388: ...leistung zu dokumentieren Folgende Tabelle dient lediglich als Wartungsplan stellt an sich aber keinen Beleg f r die Durchf h rung der Arbeiten dar INTERVALL DATUM DER WARTUNGS ARBEIT KILOMETER STAND...

Page 389: ......

Page 390: ...0E V OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH PRINTED IN JAPAN 2005 04 0 3 1 CR E F G TT R90 V TT R90E V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 S...

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