2000 YAMAHA TTR90 engine oil

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MAINTENANCE INTERVALS/
PERIODIC MAINTENANCE AND LUBRICATION
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
EC310022
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
PERIODIC MAINTENANCE AND LUBRICATION
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
* Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
* ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace if necessary.
* CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
* Front brakeCheck operation.
Adjust brake lever free play and replace brake
shoes if necessary.Every ride
* Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
* WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
* TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
* Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
* SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap base grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
* Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.
3
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PRE-OPERATION INSPECTION AND MAINTENANCE
*: Since these items requires special tools data and technical skills, they should be serviced.
SERVICE NOTES:

No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every
0.5 ~ 1.0 hour. If unit is subjected to extremely hard usage and wet weather riding, chain
must be checked constantly. See “Lubrication Intervals” for additional details.
No. 2. AIR FILTER: Remove and clean filter every 20 ~ 40 hours.
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EC321000
GENERAL INSPECTION AND MAINTENANCE
* Chassis fastenersMake sure that all nuts, bolts and screws are
properly tightened.
Tighten if necessary.
SidestandCheck operation.
Lubricate and repair if necessary.
* Spark arrester Clean.
* Front forkCheck operation and for oil leakage.
Correct accordingly.
*Rear shock
absorber assemblyCheck operation and shock absorber for oil
leakage.
Replace shock absorber assembly if necessary.
Item Routine Page
Brake Check operation/adjustment. P3-11
Engine oil Change oil as required. P3-5 ~ 7
Drive chain Check alignment/adjustment/lubrication. P3-12
Spark plug Check color/condition. P3-19
Throttle Check for proper throttle cable operation. P3-3
Air filter Foam type – must be clean and damp w/oil always P3-3 ~ 4
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P3-15 ~ 17
Fittings/fasteners Check all – tighten as necessary. —Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
3

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AIR FILTER CLEANING
1. Install:
l
Air scoop right
1

2. Install:
l
Air filter case cover
1

3. Clean:
l
Air filter element
Clean them with solvent.
NOTE:

After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:

l
Do not twist the element when squeezing
the element.
l
Leaving too much of solvent in the ele-
ment may result in poor starting.
4. Inspect:
l
Air filter element
Damage
®
Replace.
5. Apply:
l
Foam-air-filter oil or engine mixing oil
To the element.
NOTE:

Squeeze out the excess oil. Element should
be wet but not dripping.
6. Install:
l
Air filter element
1

NOTE:

Align the projection
a
on the air filter case with
the hole
b
in the air filter element.
7. Install:
l
Air filter case cover
8. Install:
l
Air scoop (right)

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ENGINE OIL LEVEL INSPECTION
1. Stand the motorcycle on a level surface.
NOTE:

l
When checking the oil level make sure that
the motorcycle is upright.
l
Place the motorcycle on a suitable stand.
WARNING

Never remove the oil tank cap just after
high speed operation. The heated oil could
spurt out causing danger. Wait until the oil
cools down to approximately 70 ˚C (158 ˚F).
2. Idle the engine more than 3 minutes
while keeping the motorcycle upright.
Then stop the engine and inspect the oil
level.
3. Remove:
l
Dipstick
1
4. Inspect:
l
Oil level
Oil level should be between maximum
a
and minimum
b
marks.
Oil level is low
®
Add oil to proper
level.
NOTE:

When inspecting the oil level, do not screw the
oil level gauge into the oil tank.
Insert the gauge lightly.
(For USA and CDN)
CAUTION:

l
Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
l
Do not allow foreign material to enter the
crankcase.
Recommended oil:
At –10 ˚C (10 ˚F) or higher

:
Yamalube 4 (10W30) or SAE
10W30 type SE/SF motor oil
At 5 ˚C (40 ˚F) or higher
õ
:
Yamalube 4 (20W40) or SAE
20W40 type SE/SF motor oil
010 30 50 70
90110
130
-20
-10 010
20 30 40
50

õ
˚C˚F

ENGINE OIL LEVEL INSPECTION

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ENGINE OIL REPLACEMENT
(Except for USA and CDN)
CAUTION:

l
Do not add any chemical additives or use
oils with a grade of CD
a or higher.
lDo not use oils labeled “ENERGY CON-
SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
lDo not allow foreign materials to enter the
crankcase.
5. Start the engine and let it warm up for
several minutes.
CAUTION:
When the oil tank is empty, never start the
engine.
6. Idle the engine more than 10 seconds
while keeping the motorcycle upright.
Then stop the engine and add the oil to
the maximum level.
7. Install:
lDipstick
ENGINE OIL REPLACEMENT
1. Start the engine and let it warm up for
several minutes.
2. Stop the engine and place an oil pan
under the drain bolt.
3. Remove:
lDipstick 1
lDrain bolt (with gasket) 2
Drain the crankcase of its oil.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SE/SF” or higher grade
(Designed primarily for motor-
cycles)-20
-4-10
140
3010
5020
6830
8640 50
104
122¡CTemp.
¡F
10W/30
10W/40
20W/40
20W/50
a
b

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PILOT AIR SCREW ADJUSTMENT
4. Install:
lGasket
lDrain bolt
New
T R..20 Nm (2.0 m · kg, 14 ft · lb)
5. Fill:
lCrankcase
Oil quantity:
Total amount:
1.0 L (0.88 Imp qt, 1.06 US qt)
Periodic oil change:
0.8 L (0.70 Imp qt, 0.85 US qt)
6. Install:
lDipstick
7. Inspect:
lEngine (for oil leaks)
lOil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION”.
PILOT AIR SCREW ADJUSTMENT
1. Adjust:
lPilot air screw 1
Adjusting steps:
lScrew in the pilot air screw until it is lightly
seated.
lBack out by the specified number of turns.
Pilot air screw:
1-3/4 turns out

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INSP
ADJFRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT
lTighten the wheel axle nut while pushing
down the drive chain.
T R..
Axle nut:
60 Nm (6.0 m • kg, 43 ft • lb)
EC36C000
FRONT FORK INSPECTION
1. Inspect:
lFront fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage ® Repair
or replace.
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
lSwingarm smooth action
Abnormal noise/unsmooth action ®
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage ® Replace.
EC36M012
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the
suitable stand under the engine.
2. Remove:
lRear shock absorber
Refer to “SWINGARM” section in the
CHAPTER 5.
3. Remove:
lSpring guide 1
NOTE:
While compressing the spring, remove the
spring guide.

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ENGCAMSHAFT AND ROCKER ARMS
REMOVAL POINTS
Rocker arm shaft
1. Remove:
lRocker arm shafts
NOTE:
Use a slide hammer bolt 1 and weight 2 to
slide out the rocker arm shafts.
Slide hammer set:
YU-1083-A
Slide hammer bolt:
90890-01085
Weight:
90890-01084
INSPECTION
Camshaft
1. Measure:
lCam lobes length a and b
Out of specification ® Replace.
Cam lobes length limit:
Intake:
a 25.4 mm (1.00 in)
b 21.0 mm (0.83 in)
Exhaust:
a 25.26 mm (0.99 in)
b 21.017 mm (0.83 in)
ASSEMBLY AND INSTALLATION
1. Apply:
lMolybdenum disulfide oil
(onto the camshaft cam lobe)
lEngine oil
(onto the camshaft bearing)
2. Install:
lCamshaft 1