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CHAS

STEERING

Order

Job name/Part name

Q’ty

Remarks

Master cylinder assembly

NOTE:

After installing all parts, refer to “CABLE
ROUTING” in CHAPTER 9, to check the
cable and lead routings.

Handlebar holder (upper)

Cable holder

Handlebar

Handlebar holder (lower)

For installation, reverse the removal proce-
dure.

Содержание RS90NL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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