Yamaha TT-R90(W) Owner'S Manual Download Page 67

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-29

2. Remove the brake pedal free play

adjusting nut, and then disconnect
the brake rod at the brake cam-
shaft lever.

3. Loosen the locknut and the drive

chain slack adjusting nut on both
ends of the swingarm.

4. Loosen the axle nut.
5. Lift the rear wheel off the ground

according to the procedure on
page 6-26.

6. Remove the axle nut and washer,

and then pull the wheel axle out.

7. Push the wheel forward, and then

remove the drive chain from the
rear sprocket.

NOTE:

The drive chain does not need to be
disassembled in order to remove and
install the wheel.

8. Remove the wheel.

EAU41651

To install the rear wheel

1. Install the drive chain onto the rear

sprocket.

2. Insert the wheel axle from the

right-hand side.

3. Adjust the drive chain slack. (See

page 6-18.)

4. Lower the rear wheel so that it is

on the ground.

5. Install the brake rod onto the brake

camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.

6. Connect the brake torque rod to

the brake shoe plate by installing
the bolt and nut, and then tighten
the bolt to the specified torque.

7. Insert a new cotter pin.
8. Tighten the axle nut to the speci-

fied torque.

9. Adjust the brake pedal position

and free play. (See page 6-17.)

1. Brake rod
2. Brake pedal free play adjusting nut

3. Brake camshaft lever

4. Wheel axle

1. Axle nut
2. Washer

3. Drive chain slack adjusting nut

4. Locknut

Tightening torques:

Brake torque rod bolt:

26 Nm (2.6 m·kgf, 19 ft·lbf)

Axle nut:

60 Nm (6.0 m·kgf, 43 ft·lbf)

U3P281E0.book Page 29 Monday, April 17, 2006 11:26 AM

Summary of Contents for TT-R90(W)

Page 1: ...3P2 28199 81 TT R90 W TT R90E W OWNER S MANUAL MANUEL DU PROPRI TAIRE BEDIENUNGSANLEITUNG...

Page 2: ...PRINTED ON RECYCLED PAPER IMPRIM SUR PAPIER RECYCL AUF RECYCLINGPAPIER GEDRUCKT YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 04 0 3 1 CR E F G...

Page 3: ...OWNER S MANUAL TT R90 W TT R90E W 3P2 28199 81 E0 U3P281E0 book Page 1 Monday April 17 2006 11 26 AM...

Page 4: ...U3P281E0 book Page 2 Monday April 17 2006 11 26 AM...

Page 5: ...MANUAL COMPLETELY BEFORE OPERATING YOUR MOTORCYCLE MAKE SURE YOU UNDER STAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE NEVER OPERATE A MOTORCYCLE WITHOUT...

Page 6: ...IN THE OWNER S MANUAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL...

Page 7: ...your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING TH...

Page 8: ...C STREET ROAD OR HIGHWAY SUCH USE IS PROHIBITED BY LAW THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS PLEASE CHECK YOUR LOCAL RIDING LAW...

Page 9: ...S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition March 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printe...

Page 10: ...e emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing the cowling and panel 6 6 Checking the spark plug 6 7 Engine oil 6 8 Cleaning the air filter element...

Page 11: ...el 6 28 Troubleshooting 6 30 Troubleshooting chart TT R90 W 6 31 Troubleshooting chart TT R90E W 6 32 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage TT R90 W 7 3 Storage TT R90E W 7 4 SPECIFICATIONS...

Page 12: ...he handlebar and both feet on the operator footrests during operation to maintain control of the motor cycle Never ride under the influence of alcohol or other drugs Be sure the transmission is in neu...

Page 13: ...ries Use extreme caution when selecting and installing any ac cessories Keep these guidelines in mind for mounting accessories in addition to those provided under Loading Never install accessories or...

Page 14: ...and exhaust pipe s muffler s may be hot therefore park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas Do not park the motorcycle on a slope or soft gr...

Page 15: ...TY INFORMATION 1 4 1 EAU41370 Location of important labels Please read the following important labels carefully before operating this vehicle For Canada U3P281E0 book Page 4 Monday April 17 2006 11 26...

Page 16: ...g control if you carry a passenger NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS You can collide with another vehicle if you operate this vehicle on a public road ALWAYS WEAR AN APPROVED MOTORCYCLE HELME...

Page 17: ...SAFETY INFORMATION 1 6 1 Except for Canada U3P281E0 book Page 6 Monday April 17 2006 11 26 AM...

Page 18: ...iliser ce v hicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este veh culo lea el Manual del Propietario 5PA 21568 00 TIRE INFORMATION Cold tire normal press...

Page 19: ...ft view 1 Fuel cock page 3 5 2 Starter choke lever page 3 6 3 Battery TT R90E W page 6 24 4 Engine oil drain bolt page 6 8 5 Shift pedal page 3 2 6 Throttle stop screw page 6 13 U3P281E0 book Page 1 M...

Page 20: ...e 6 12 2 Seat page 3 7 3 Kickstarter page 3 6 4 Fuse TT R90E W page 6 26 5 Fuel tank page 3 3 6 Air filter element page 6 10 7 Spark plug cap page 6 7 8 Brake pedal page 3 2 9 Engine oil filler cap pa...

Page 21: ...truments 1 Left handlebar switch page 3 1 2 Brake lever page 3 2 3 Throttle grip page 6 14 4 Right handlebar switch TT R90E W page 3 1 5 Fuel tank cap page 3 3 6 Main switch TT R90E W page 3 1 U3P281E...

Page 22: ...41890 Engine stop switch TT R90 W Set this switch to before starting the engine Set this switch to to stop the engine EAU12660 Engine stop switch TT R90E W Set this switch to before starting the engin...

Page 23: ...l is at the bottom po sition EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The bra...

Page 24: ...s Avoid spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU41930 For Canad...

Page 25: ...e of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleade...

Page 26: ...to the carburetor while filtering it al so The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run...

Page 27: ...gine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EA...

Page 28: ...rly se cured before riding EAU37490 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright WARNING EWA14190 T...

Page 29: ...f system pre vents starting when the transmission is in gear Periodically check the operation of the starting circuit cut off system according to the following procedure WARNING EWA10250 If a malfunct...

Page 30: ...tch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer 6 Shift the transmission into the neutral position 7 Push the start switch Does the engine start The neutral s...

Page 31: ...uences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used...

Page 32: ...ee play Adjust if necessary 6 17 6 18 Throttle grip Make sure that operation is smooth Check cable free play If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing...

Page 33: ...ation is smooth Lubricate lever pivoting point if necessary 6 22 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 22 Chassis fasteners Make sure that all nuts bolts and scre...

Page 34: ...ntact the ground and distract the opera tor resulting in a possible loss of control EAU41670 Starting and warming up a cold engine TT R90 W 1 Turn the fuel cock lever to ON 2 Set the engine stop switc...

Page 35: ...hrottle See page 3 6 5 Start the engine by pushing the start switch 6 After starting the engine move the starter choke back halfway CAUTION ECA11130 For maximum engine life always warm the engine up b...

Page 36: ...ing gears to avoid damaging the engine transmis sion and drive train which are not designed to withstand the shock of shifting when the throt tle grip is open EAU39910 To start out and accelerate 1 Cl...

Page 37: ...lowed with a substantial rest period for the engine To allow the engine to cool down from the temporary buildup of heat cruise at a lower engine speed After the first 5 hours of operation thor oughly...

Page 38: ...in switch and then turn the fuel cock lever to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them...

Page 39: ...NTENANCE PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEA SURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTE NANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONT...

Page 40: ...tional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer...

Page 41: ...hours 5000 km 3000 mi or 12 months or 150 hours 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and ad...

Page 42: ...ake shoes if necessary 4 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 5 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if nece...

Page 43: ...pose grease lightly 14 Spark arrester Clean 15 Front fork Check operation and for grease leakage Replace if necessary 16 Shock absorber assem bly Check operation and for oil leakage Replace if necessa...

Page 44: ...A To remove the cowling 1 Remove the seat See page 3 7 2 Remove the bolt and then take the cowling off To install the cowling 1 Place the cowling in the original position and then install the bolt 2...

Page 45: ...that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE If the spark plug shows a distinctly dif fe...

Page 46: ...cycle on a level surface and hold it in an upright po sition NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false r...

Page 47: ...also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY C...

Page 48: ...lvent and then squeeze the re maining solvent out WARNING EWA10430 Use only a dedicated parts cleaning solvent To avoid the risk of fire or explosion do not use gasoline or solvents with a low flash p...

Page 49: ...inder s may become excessively worn 8 Install the air filter case cover by in stalling the screws NOTE Make sure that the spark plug cable is routed as shown 9 Install the panel To clean the air filte...

Page 50: ...ct a well ventilated area free of combustible materials to clean the spark arrester 1 Remove the tailpipe by removing the bolt and then pulling it out of the muffler 2 Tap the tailpipe lightly and the...

Page 51: ...speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart NOTE A diagnostic tachometer is needed to make this adjustment 1...

Page 52: ...knut 2 To increase the throttle cable free play turn the adjusting nut in direc tion a To decrease the throttle cable free play turn the adjusting nut in direction b 3 Tighten the locknut EAU21401 Val...

Page 53: ...ass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately Tire information This motorcycle is equipped with spoke wheels and tube tires WARNING EWA10460 The...

Page 54: ...the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a...

Page 55: ...5 Loosen the locknut at the brake shoe plate 6 To increase the brake lever free play turn the adjusting nut in direc tion a To decrease the brake le ver free play turn the adjusting nut in direction...

Page 56: ...s as a set NOTE Be sure to measure the brake lining at the thinnest portion EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22771 To ch...

Page 57: ...ng the alignment marks on each side of the swingarm make sure that both adjusting nuts are in the same po sition for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load t...

Page 58: ...The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Remove all dirt and mud from the drive chain with a brush or cloth NOTE For a thorough cleaning have a Yamaha...

Page 59: ...ca bles as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi ti...

Page 60: ...to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swing...

Page 61: ...o check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checkin...

Page 62: ...eel bearings EAU34221 Battery TT R90E W The battery is located behind cowling A See page 6 6 This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no ne...

Page 63: ...discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge i...

Page 64: ...ycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Chec...

Page 65: ...ly support the motor cycle so that there is no danger of it falling over 1 Loosen the locknut at the brake le ver and then turn the adjusting bolt fully in direction a 2 Loosen the axle nut 3 Lift the...

Page 66: ...ge 6 17 6 While applying the front brake push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU41641 To remove the rear wheel WARNING EWA10820 It is a...

Page 67: ...o the rear sprocket 2 Insert the wheel axle from the right hand side 3 Adjust the drive chain slack See page 6 18 4 Lower the rear wheel so that it is on the ground 5 Install the brake rod onto the br...

Page 68: ...e poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair...

Page 69: ...is compression There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct...

Page 70: ...he ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Y...

Page 71: ...irt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper c...

Page 72: ...rome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing...

Page 73: ...to pro tect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the s...

Page 74: ...ark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the...

Page 75: ...YCLE CARE AND STORAGE 7 5 7 C 90 F For more information on storing the battery see page 6 24 NOTE Make any necessary repairs before storing the motorcycle U3P281E0 book Page 5 Monday April 17 2006 11...

Page 76: ...ment Forward inclined single cylinder Displacement 89 0 cm 5 43 cu in Bore stroke 47 0 51 8 mm 1 85 2 04 in Compression ratio 8 50 1 Starting system TT R90 Kickstarter TT R90E Electric starter and kic...

Page 77: ...ary reduction system Spur gear Primary reduction ratio 67 18 3 722 Secondary reduction system Chain drive Secondary reduction ratio 35 14 2 500 Transmission type Constant mesh 3 speed Operation Left f...

Page 78: ...110 0 mm 4 33 in Rear suspension Type Swingarm monocross Spring shock absorber type Coil spring gas oil damper Wheel travel 95 0 mm 3 74 in Electrical system Ignition system CDI Battery Model TT R90E...

Page 79: ...ntification number TT R90E W The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identific...

Page 80: ...abel is affixed to the frame under the seat See page 3 7 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Mod...

Page 81: ...h TT R90E W 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Model label 9 2 P Parking TT R90E W 5 5 Parking TT R90 W 5 4 Part locations 2...

Page 82: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006 04 0 3 1 CR E U3P281E0 book Page 1 Monday April 17 2006 11 26 AM...

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