2000 YAMAHA TTR90 oil

EC085001
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols
1
to
6
are designed as
thumb tabs to indicate the chapter’s number
and content.
1
General information
2
Specifications
3
Regular inspection and adjustments
4
Engine
5
Chassis
6
Electrical
Illustrated symbols
7
to
D
are used to identify
the specifications appearing in the text.
7
With engine mounted
8
Special tool
9
Filling fluid
0
Lubricant
A
Tightening
B
Specified value, Service limit
C
Engine speed
DResistance (W), Voltage (V), Electric current (A)
Illustrated symbols E to I in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
EApply gear oil
FApply engine oil
GApply molybdenum disulfide oil
HApply lightweight lithium-soap base grease
IApply molybdenum disulfide grease
Illustrated symbols J to K in the exploded
diagrams indicate where to apply a locking
agent J and when to install a new part K.
JApply locking agent (LOCTITE®)
KReplace 12
34
56
78
90
AB
CD
EFG
HIJ
K
GEN
INFOSPEC
INSP
ADJENG
CHAS–+ELEC
T R..
GME
MLTLS
New

CHAPTER 4
ENGINE
CARBURETOR
......................................... 4-1
CYLINDER HEAD
..................................... 4-8
CAMSHAFT AND ROCKER ARMS
....... 4-13
VALVES AND VALVE SPRINGS
........... 4-16
CYLINDER AND PISTON
....................... 4-21
CLUTCH
.................................................. 4-27
KICK AXLE
............................................. 4-33
SHIFT SHAFT
......................................... 4-34
OIL PUMP
............................................... 4-36
CDI MAGNETO
....................................... 4-39
CRANKCASE AND CRANKSHAFT
....... 4-41
SHIFT FORK, SHIFT CAM AND
TRANSMISSION
..................................... 4-44
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL
...... 5-1
FRONT FORK
........................................... 5-6
HANDLEBAR
............................................ 5-9
STEERING
.............................................. 5-10
SWINGARM
............................................ 5-11
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM
................................... 6-1
IGNITION SYSTEM
................................... 6-2
CARBURETOR HEATING SYSTEM
........ 6-6
MAINTENANCE RECORD
....................... 6-9

1 - 3
GEN
INFO

IMPORTANT INFORMATION
EC130000
IMPORTANT INFORMATION
EC131002
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassem-
bly.
2. Use proper tools and cleaning equip-
ment. Refer to “SPECIAL TOOLS” sec-
tion.
3. When disassembling the machine, keep
mated parts together. They include
gears, cylinders, pistons, and other
mated parts that have been “mated”
through normal wear. Mated parts must
be reused as an assembly or replaced.
4. During the machine disassembly, clean
all parts and place them in trays in the
order of disassembly. This will speed up
assembly time and help assure that all
parts are correctly reinstalled.
5. Keep away from fire.
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.

1 - 4
GEN
INFO

IMPORTANT INFORMATION
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
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 nut has been properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s)
1
and oil seal(s)
2
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:

Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
EC136000
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace pis-
ton pin clips after one use. Replace dis-
torted circlips. When installing a circlip
1
, make sure that the sharp-edged cor-
ner
2
is positioned opposite to the thrust
3
it receives. See the sectional view.
4
Shaft

GEN
INFO

1 - 6
SPECIAL TOOLS
EC140001
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:

l
For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “YS-”.
lFor others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1083-A
90890-01084
90890-01085Small slide hammer set
Weight
Slide hammer
These tools are used when removing or installing the
rocker arm shafts.YU-1083-A 90890-01084
90890-01085
YU-01268, 90890-01268 Ring nut wrench
This tool is used when loosen the steering ring nut to
specification.YU-01268 90890-01268
YU-03112, 90890-03112 Yamaha pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-03112 90890-03112
YU-8036-1
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-1 90890-03113
YM-01253, 90890-01253 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-01253 90890-01253
YM-01300
90890-01294Damper rod holder set
Damper rod holder
Use this tool to remove and install the damper rod.YM-01300 90890-01294
YM-01312-A, 90890-01312Fuel level gauge
This gauge is used to measure the fuel level in the
float chamber.YM-01312-A 90890-01312

GEN
INFO
1 - 7
SPECIAL TOOLS
YM-01326, 90890-01326 T-handle
This tool is used for holding the damper rod holder
when removing or installing the damper rod holder.YM-01326 90890-01326
YM-1369, 90890-01186 Fork seal driver attachment
This tool is used to installing the oil seal.YM-1369 90890-01186
YM-08035, 90890-01311 Valve adjusting tool
This tool is necessary for adjusting valve clearance.YM-08035 90890-01311
YM-33963, 90890-01184 Fork seal driver weight
This tool is used to installing the oil seal.YM-33963 90890-01184
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
YM-33975, 90890-01403 Ring nut wrench
This tool is used when tighten the steering ring nut to
specification.YM-33975 90890-01403
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
YS-01880, 90890-01701 Sheave holder
This tool is used for when loosening or tightening the
flywheel magneto securing nut.YS-01880 90890-01701
YU-33270, 90890-01362 Flywheel puller
This tool is used to remove the rotor.YU-33270 90890-01362
Part number Tool name/How to use Illustration

GEN
INFO
OUTILS SPECIAUX
Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point
complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à
l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci. La forme et le numéro de
pièce des outils spéciaux diffèrent selon les pays. Voilà pourquoi il y a parfois deux versions d’un outil. La
liste suivante permet d’éviter toute erreur lors de la commande de pièces.
N.B.:
lPour les USA et le Canada, utiliser les numéros de pièce qui commencent par “YM-”, “YU-” ou “YS-”.
lPour les autres pays utiliser les numéros de pièce qui commencent par “90890-”.
Numéros de pièce Nom et usage de l’outil Illustration
YU-1083-A
90890-01084
90890-01085Kit de petit extracteur à inertie
Masse
Extracteur à inertie
Ces outils permettent de déposer et de remonter les axes
de culbuteur.YU-1083-A 90890-01084
90890-01085
YU-01268, 90890-01268 Clé pour écrou annulaire
Cet outil est utilisé pour desserrer l’écrou de bague de
direction aux spécifications.YU-01268 90890-01268
YU-03112, 90890-03112 Multimètre Yamaha
Utiliser cet outil pour examiner la résistance de bobine, la
tension de sortie et l’intensité.YU-03112 90890-03112
YU-8036-1
90890-03113Compte-tours inductif
Compte-tours moteur
Cet outil est nécessaire pour observer la vitesse de rotation
du moteur.YU-8036-1 90890-03113
YM-01253, 90890-01253 Compresseur de ressort de soupape
Cet outil sert à déposer et installer les ensembles soupapes.YM-01253 90890-01253
YM-01300
90890-01294Jeu d’outils de maintien de tige d’amortisseur
Poignée de tige d’amortisseur
Utiliser ces outils pour déposer et poser la tige d’amortis-
seur.YM-01300 90890-01294
YM-01312-A, 90890-01312Jauge de niveau du carburant
Cette jauge sert à mesurer le niveau de carburant dans la
cuve à niveau constant.YM-01312-A 90890-01312
OUTILS SPECIAUX
1 - 6

GEN
INFO
1 - 12
STARTING AND OPERATION
STARTING AND OPERATION
CAUTION:
Prior to operating the machine, perform
steps listed in pre-operation check list.
WARNING
Never start your engine or let it run for any
length of time in a closed area. The exhaust
fumes are poisonous and can cause loss of
consciousness and death within a short
time. Always operate your machine in an
area with adequate ventilation.
STARTING A COLD ENGINE
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
1. Turn the fuel cock to “ON”.
2. Operate the starter (choke) and com-
pletely close the throttle grip.
3. Slide the “ENGINE STOP” switch to the
“”.
4. Kick the kick starter with full strength to
start the engine.
5. After the engine starts, warm up for one
or two minutes. Make sure the stater
(choke) is returned to the original position
before riding.
STARTING A WARM ENGINE
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke)
should not be used. The throttle should be
opened slightly.
CAUTION:
See “Break-in Section” prior to operating
engine for the first time.WARMING UP
To get maximum engine life, always “warm-up”
the engine before starting off. Never acceler-
ate hard with a cold engine! To see whether or
not the engine is warm, see if it responds to
throttle normally with the stater (choke) turned
off.
WARNING
Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.
ENGINE BREAK-IN
1. Prior to starting, fill fuel tank with gasoline
and oil tank with specified oil.
2. Allow engine to warm up. Check engine
idling speed. Check operating controls
and engine stop switch operation.
3. Operate machine in lower gears at mod-
erate throttle setting for 3 ~ 5 minutes.
Check spark plug condition.
4. Allow engine to cool. Repeat procedure,
running for 5 minutes. Very briefly, shift to
higher gears and check full throttle
response. Check spark plug condition.
5. Allow engine to cool. Repeat procedure,
running for 5 minutes. Full throttle and
higher gears may be used, but avoid sus-
tained full throttle operation. Check spark
plug condition.
6. Allow engine to cool. Remove top end and
inspect. Remove “high” spots on piston
with No.600 grit, wet sandpaper.
Clean, and carefully reassemble.
7. Check entire unit for loose or misadjusted
fittings/controls/fasteners.
8. Re-start engine and check through entire
operating range thoroughly. Stop. Check
spark plug condition. Re-start. After 10 ~
15 minutes operation, machine is ready
to ride.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.