2001 YAMAHA TTR90 lock

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
D
Resistance (
W
), Voltage (V), Electric current (A)
Illustrated symbols
E
to
H
in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
E
Apply engine oil
F
Apply molybdenum disulfide oil
G
Apply lightweight lithium-soap base grease
H
Apply molybdenum disulfide grease
Illustrated symbols
I
to
J
in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
I
Apply locking agent (LOCTITE
®
)
J
Use new one
12
34
56
78
90
AB
CD
E

F
G

H
IJ
GEN
INFOSPEC
INSP
ADJENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

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

1 - 11
GEN
INFO

CONTROL FUNCTIONS/FUEL
FUEL TANK CAP
Remove the fuel tank cap
1 by turning
counter-clockwise.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine.
FUEL
Use regular gasoline. Always use fresh, name
brand gasoline.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine. Do not fill the fuel
tank above the bottom of the filler tube 1
as shown in the illustration or it may over-
flow when the fuel heats up later and
expands.
aFuel level
Recommended fuel:
For USA:
Unleaded fuel
For CDN and EUROPE:
Rgular unleaded gasoline
For AUS:
Unleaded fuel only
For NZ:
Regular gasoline
Fuel tank capacity:
Total:
4.2 L (0.92 lmp gal, 1.11 US gal)
Reserve:
0.5 L (0.11 lmp gal, 0.13 US gal)

SPEC

2 - 6
Stem runout limit ---- 0.02 mm
(0.0008 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
Valve spring:
Free length IN 28.32 mm (1.11 in) 26.9 mm
(1.06 in)
EX 28.32 mm (1.11 in) 26.9 mm
(1.06 in)
Set length (valve closed) IN 24.2 mm (0.95 in) ----
EX 24.2 mm (0.95 in) ----
Compressed pressure
(installed) IN 90.4 ~ 104.1 N
(9.2 ~ 10.6 kg, 20.32 ~ 23.40 lb)----
EX 90.4 ~ 104.1 N
(9.2 ~ 10.6 kg, 20.32 ~ 23.40 lb)----
Tilt limit IN ---- 2.5˚/1.2 mm
(2.5˚/0.05 in)
EX ---- 2.5˚/1.2 mm
(2.5˚/0.05 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ---- Item Standard Limit
*

MAINTENANCE SPECIFICATIONS

SPEC

2 - 10
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Cylinder head nut M8
´
1.25 4 22 2.2 16
Cylinder head bolt M6
´
1.0 2 10 1.0 7.2
Spark plug M10
´
1.0 1 13 1.3 9.4
Camshaft sprocket cover bolt M6
´
1.0 2 7 0.7 5.1
Tappet cover M45
´
1.5 2 18 1.8 13
Exhaust pipe stud bolt M6
´
1.0 2 7 0.7 5.1
Rotor nut M12
´
1.25 1 48 4.8 35
Timing chain guide (rear) M6
´
1.0 2 10 1.0 7.2
Valve clearance adjust screw locknut M5
´
0.5 2 7 0.7 5.1
Camshaft sprocket M8
´
1.25 1 20 2.0 14
Camshaft bearing retainer M6
´
1.0 1 10 1.0 7.2
Timing chain tensioner cap bolt M8
´
1.25 1 8 0.8 5.8
Timing chain tensioner M6
´
1.0 2 10 1.0 7.2
Oil pump M6
´
1.0 2 7 0.7 5.1
Drain bolt M12
´
1.5 1 20 2.0 14
Carburetor joint (cylinder head side) M6
´
1.0 2 7 0.7 5.1
Carburetor joint (carburetor side) M6
´
1.0 2 7 0.7 5.1
Air filter case M6
´
1.0 2 7 0.7 5.1
Exhaust pipe M6
´
1.0 2 7 0.7 5.1
Exhaust pipe protector M6
´
1.0 7 7 0.7 5.1
Silencer M8
´
1.25 1 24 2.4 17
Silencer protector M5
´
0.8 2 4 0.4 2.9
Crankcase M6
´
1.0 9 10 1.0 7.2
Crankcase cover (left) M6
´
1.0 8 7 0.7 5.1
Drive sprocket cover M6
´
1.0 2 7 0.7 5.1
Crankcase cover (right) M6
´
1.0 9 7 0.7 5.1
Timing plug M14
´
1.5 1 7 0.7 5.1
Crankshaft end cover M32
´
1.5 1 7 0.7 5.1
Cylinder head stud bolt M8
´
1.25 4 13 1.3 9.4
Kick crank M6
´
1.0 1 10 1.0 7.2
Primary drive gear M12
´
1.0 1 50 5.0 36
Pressure plate M5
´
0.8 4 6 0.6 4.3
Clutch boss M14
´
1.0 1 60 6.0 43
Main axle bearing retainer M6
´
1.0 1 10 1.0 7.2
Shift pedal M6
´
1.0 1 8 0.8 5.8
Clutch adjust screw locknut M6
´
1.0 1 8 0.8 5.8
Pickup coil M6
´
1.0 2 10 1.0 7.2
Stator assembly M6
´
1.0 3 10 1.0 7.2
MAINTENANCE SPECIFICATIONS

SPEC

2 - 13
NOTE:

l
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 1 Nm (0.1 m • kg, 0.7 ft • lb).
l
-marked portion shall be checked for torque tightening after break-in or before each ride.Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Engine mounting:
Engine and frame (front-upper) M8
´
1.25 1 30 3.0 22
Engine and frame (rear-upper) M8
´
1.25 1 26 2.6 19
Engine and frame (rear-lower) M10
´
1.25 1 40 4.0 29
Starter cable and frame M11
´
1.25 1 1 0.1 0.7
Pivot shaft and nut M10
´
1.25 1 30 3.0 22
Handle crown and steering shaft M10
´
1.25 1 40 4.0 29
Front fork cap bolt M20
´
1.0 2 40 4.0 29
Under bracket and front fork M10
´
1.25 2 33 3.3 24
Damper rod bolt M8
´
1.25 2 20 2.0 14
Handle crown and handlebar holder (lower) M10
´
1.25 2 40 4.0 29
Handlebar holder (upper) M6
´
1.0 4 13 1.3 9.4
Front brake cable holder and front fork M6
´
1.0 2 7 0.7 5.1
Steering ring nut M25 1 Refer to NOTE.
Fuel tank and fuel cock M6
´
1.0 2 7 0.7 5.1
Fuel tank and frame M6
´
1.0 2 7 0.7 5.1
Grab bar and frame M6
´
1.0 4 13 1.3 9.4
Front brake camshaft lever and camshaft M6
´
1.0 1 7 0.7 5.1
Rear brake camshaft lever and camshaft M6
´
1.0 1 7 0.7 5.1
Front wheel axle nut M10
´
1.25 1 35 3.5 25
Rear brake shoe plate tension bar M8
´
1.25 2 26 2.6 19
Wheel drive hub and driven sprocket M8
´
1.25 4 25 2.5 18
Rear wheel axle nut M12
´
1.25 1 60 6.0 43
Wheel nipple (spoke) — 64 2 0.2 1.4
Chain case M5
´
0.8 5 4 0.4 2.9
Chain puller locknut M6
´
1.0 2 3 0.3 2.2
Footrest and frame M8
´
1.25 2 30 3.0 22
MAINTENANCE SPECIFICATIONS

2 - 16
SPEC

CABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1
Crankcase breather hose
2
Wire harness
3
CDI magneto lead
4
Starter cable
5
Carburetor heating lead
6
Engine stop switch lead
7
Thermo switch
8
Thermo switch lead
9
Spark plug lead
0
Throttle cable
A
Cable holder
B
Fuel tank breather hose
C
Brake cable

After fastening the starter cable, CDI magneto lead, wire harness and
thermo switch lead, cut off any excess from the plastic locking tie end.
õ
Pass the ignition coil lead through the lead guide.
‚
Fasten the engine stop switch lead with the plastic bands.
ë
Pass the brake cable through the cable guides.
12345
9
0
B A
6
C 1
õ
‚
ë
ë
A
A
67
8
20 ~ 30 mm
(0.79 ~ 1.18 in)

2 - 18
SPEC

CABLE ROUTING DIAGRAM

Pass the fuel tank breather hose through the
cable guide.
õ
Pass the throttle cable and engine stop switch
lead through the cable guide.
‚
Pass the air vent hose through the hose guide.
ë
Fasten the CDI unit lead and rectifier/regulator
lead with the plastic clamp.
ä
Align the tape on the rectifier/regulator lead with
the plastic clamp.
ì
After fastening the engine stop switch lead, cut
off any excess from the plastic locking tie end.
í
Pass the CDI unit lead through the lead guide.
A
123
4
5
6
7
8
9
0A
C
E B
F G H I
6
6 J L
5
H
B8 K
7 ‚
ä
‚
ì
í
B - B C - C
D - DF - FE
õ
ë
D
D
B
D
A A B
B B
B
C
C C
CE
B D
B
D
F F F F