2001 YAMAHA TTR90 Brake cable

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 “Engine 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
Brake-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially
of slack cables and drive chain and loose
spokes.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.

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 - 17
SPEC

CABLE ROUTING DIAGRAM
1
Cable guide
2
Brake cable
3
Throttle cable
4
Fuel tank breather hose
5
Engine stop switch lead
6
Air vent hose
7
Air intake duct
8
Ignition coil
9
Cable guide
0
Wire harness
A
Damper
B
CDI unit lead
C
CDI unit
D
Rectifier/regulator lead
E
Rectifier/regulator
F
Crankcase breather hose
G
Carburetor breather hose
H
Spark plug lead
I
Fuel hose
J
Starter cable
K
CDI magneto lead
L
Thermo switch
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

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS/
PERIODIC MAINTENANCE AND LUBRICATION
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
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
3

3 - 2
INSP
ADJ

PRE-OPERATION INSPECTION AND MAINTENANCE
*: Since these items requires special tools data and technical skills, they should be serviced.
*
1

: For USA
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.
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.
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
*
1

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 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. P2-13Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
3

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INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Brake lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Brake cable endUse Yamaha cable lube or equivalent on these
areas.
õUse SAE 10W-30 motor oil or suitable chain
lubricants.
‚Lubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC
78

5 - 1
CHAS

EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL AND FRONT BRAKE
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Bolt (brake cable holder) 1 Only loosening.
2 Brake cable 1 Disconnect at the lever side.
3 Wheel axle nut 1
4 Front wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9Bearing
2Refer to “REMOVAL POINTS”.
WARNING
Support the machine securely so there is nodanger of it falling over.
2
31
3

FRONT WHEEL AND REAR WHEEL
5