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Yamaha TT-R90(T) User Manual

Yamaha TT-R90(T)
364 pages
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5HN-28199-85
TT-R90(T)
TT-R90E(T)
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGS-HANDBUCH

Table of Contents

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Yamaha TT-R90(T) Specifications

General IconGeneral
Displacement89cc
IgnitionCDI
Final DriveChain
Front SuspensionTelescopic fork
Engine TypeAir-cooled, SOHC, 4-stroke, single cylinder

Summary

General Information

Description of Motorcycle Components

Identifies and describes major motorcycle components and controls, including switches, levers, and pedals.

Machine Identification Numbers

Explains how to find and use key identification numbers for the machine, such as VIN and engine serial number.

Important Operational Information

Provides crucial pre-operation advice, warnings, handling instructions, and preparation for disassembly.

Special Tools for Maintenance

Lists and illustrates essential specialized tools required for maintenance, tune-up, and assembly procedures.

Control Functions and Operation

Details the operation and function of main switches, levers, pedals, and starting procedures for the motorcycle.

Fuel Information and Warnings

Specifies the type of fuel, tank capacity, and important warnings related to fueling and gasoline.

Starting and Operation Procedures

Guides on how to properly start the engine, warm it up, and initial break-in procedures for the motorcycle.

Specifications and Diagrams

General Specifications

Lists general technical data including dimensions, weight, engine type, and basic chassis information.

Torque Specifications and Unit Definitions

Provides standard torque values for fasteners and defines common measurement units used in the manual.

Cable Routing Diagrams

Illustrates the correct routing and placement of electrical and control cables on the motorcycle.

Regular Inspection and Adjustments

Maintenance Intervals and Lubrication

Outlines recommended maintenance schedules based on time and usage intervals, including lubrication points.

Pre-Operation Inspection and Maintenance

Details essential checks and tasks to perform before operating the motorcycle to ensure it is in good condition.

Throttle Cable Adjustment and Air Filter Cleaning

Explains how to adjust the throttle cable free play and clean or replace the air filter element.

Engine Oil Level Inspection and Replacement

Provides steps for checking engine oil level using the dipstick and the procedure for oil replacement.

Pilot Air Screw and Idle Speed Adjustment

Guides on adjusting the pilot air screw and engine idle speed for optimal performance.

Valve Clearance Adjustment Procedures

Details the process for checking and adjusting valve clearance when the engine is cool.

Brake Adjustments

Explains how to check and adjust the free play for both front and rear brake levers and pedals.

Drive Chain Slack Adjustment

Describes the procedure for checking and adjusting the drive chain slack and alignment.

Front Fork and Rear Shock Absorber Inspection and Adjustment

Covers inspection of front forks and rear shock absorbers, including spring preload adjustment.

Tire Pressure Check and Adjustment

Details how to measure and adjust tire pressure, including notes on cold tire checks.

Wheel Inspection and Steering Head Adjustment

Covers inspection of spokes, wheel runout, bearings, and steering head play adjustment.

Battery Inspection and Charging (TT-R90E)

Provides safety precautions and procedures for inspecting and charging the motorcycle's battery.

Fuse Inspection (TT-R90E)

Explains how to inspect and replace fuses, emphasizing safety precautions to prevent short circuits.

Engine System

Carburetor Removal and Inspection

Details carburetor removal, disassembly, inspection of components, and adjustments.

Cylinder Head Removal and Installation

Provides steps and parts for removing, inspecting, and installing the cylinder head assembly.

Camshaft and Rocker Arms Service

Covers the removal, inspection, and installation of the camshaft, rocker arms, and related components.

Valves and Valve Springs Procedures

Details removal, inspection, and installation of valves, springs, seats, and guides.

Cylinder and Piston Inspection

Covers inspection of cylinder and piston walls, and measuring piston-to-cylinder clearance.

Clutch System Maintenance

Details removal, disassembly, inspection, and assembly of clutch components and systems.

Kick Axle Removal and Disassembly

Outlines the procedure and parts for removing and disassembling the kick axle assembly.

Shift Shaft Removal and Installation

Details the steps and parts for removing and installing the shift shaft and related components.

Oil Pump Inspection and Service

Covers oil pump removal, disassembly, inspection of clearances, and filter/strainer service.

CDI Magneto (TT-R90) Service

Details the removal and inspection of the CDI magneto and stator assembly.

CDI Magneto and Starter Clutch (TT-R90E) Service

Covers removal, inspection, and assembly of CDI magneto and starter clutch components.

Crankcase and Crankshaft Service

Details the steps for separating the crankcase and removing/inspecting the crankshaft.

Transmission System Service

Outlines removal and assembly procedures for shift forks, shift cam, and transmission components.

Chassis System

Front and Rear Wheel Service

Details the removal and inspection of the front and rear wheels, including brake components.

Front Fork Service Procedures

Covers removal, disassembly, inspection, and assembly of the front fork and its components.

Handlebar Removal and Installation

Details the procedure and parts for removing and installing the handlebar and its controls.

Steering Head Inspection and Adjustment

Covers inspecting steering shaft smoothness and adjusting the steering head nut for proper play.

Swingarm Service Procedures

Details the steps and parts for removing the swingarm, rear shock absorber, and related components.

Electrical System

Electrical Components and Wiring Diagram

Identifies electrical components and provides a visual wiring diagram for the motorcycle's system.

Ignition System Inspection and Troubleshooting

Outlines systematic steps to diagnose ignition system faults, including spark plug and coil tests.

Electric Starting System (TT-R90E) Operation and Inspection

Explains starter system operation, safety interlocks, and provides inspection steps for components.

Charging System (TT-R90E) Inspection

Outlines steps to diagnose charging system issues, checking fuses, battery, voltage, and coil resistance.

Carburetor Heating System Inspection

Provides steps to diagnose problems with the carburetor heating system, including thermo switch and coil tests.

Maintenance Record

A logbook for recording scheduled maintenance services, dates, mileage, and dealer information.

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