2001 YAMAHA TTR90 Owners Manual

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 - 11
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Angular bearing ----
Front suspension:
Front fork travel 110 mm (4.33 in) ----
Fork spring free length 425.1 mm (16.74 in) 417 mm (16.4 in)
Fork spring fitting length 415.1 mm (16.34 in) ----
Spring rate, STD K = 3.4 N/mm
(0.35 kg/mm, 19.41 lb/in)----
Optional spring/spacer No ----
Oil capacity 64 cm
3

(2.26 lmp oz, 2.16 US oz) ----
Oil level 185 mm (7.28 in) ----
Oil grade Fork oil 15W or equivalent ----
Rear suspension:
Shock absorber travel 48 mm (1.89 in) ----
Spring free length 169 mm (6.65 in) ----
Fitting length 165 mm (6.5 in) ----
Spring rate, STD K = 45.6 N/mm
(4.65 kg/mm, 260 lb/in)----
Optional spring No ----
Enclosed gas pressure 2,000 kPa
(20 kg/cm
2

, 290 psi)----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)
Side clearance ---- 0.3 mm (0.01 in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 14
´
1.40/steel ----
Rear rim size/material 12
´
1.60/steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID420(I)/DAIDO ----
Number of links 86 links ----
Chain slack 40 ~ 53 mm (1.6 ~ 2.1 in) ----
Chain length (10 links) ---- 121.9 mm
(4.80 in)
MAINTENANCE SPECIFICATIONS

SPEC

2 - 12
Drum brake:
Front drum brake type Leading, trailing ----
Rear drum brake type Leading, trailing ----
Front drum inside diameter 95 mm (3.74 in) 96 mm (3.78 in)
Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Front lining thickness 3 mm (0.12 in) 2 mm (0.08 in)
Rear lining thickness 4 mm (0.16 in) 2 mm (0.08 in)
Front shoe spring free length 32.7 mm (1.29 in) ----
Rear shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:
Brake lever free play (lever end) 10 ~ 20 mm (0.39 ~ 0.79 in) ----
Brake pedal free play 10 ~ 20 mm (0.39 ~ 0.79 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
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

SPEC

2 - 14
EC212300
ELECTRICAL
Item Standard Limit
CDI:
Magneto-model/manufacturer F5HN 00/YAMAHA ----
Source coil resistance (color) 688 ~ 1,032
W
at 20 ˚C (68 ˚F)
(Brown – Green)----
Pickup coil resistance (color) 248 ~ 372
W
at 20 ˚C (68 ˚F)
(Red – White)----
CDI unit-model/manufacturer 4GL-20/YAMAHA ----
Ignition coil:
Model/manufacturer 4KJ-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28
W
at 20 ˚C (68 ˚F) ----
Secondary winding resistance 6.3 ~ 9.5 k
W
at 20 ˚C (68 ˚F) ----
Spark plug cap:
Type Resin ----
Resistance 10 k
W
at 20 ˚C (68 ˚F) ----
MAINTENANCE SPECIFICATIONS

2 - 15
SPEC

GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
EC220001
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
EC230000
DEFINITION OF UNITS
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3

meter
10
-2

meterLength
Length
kg kilogram 10
3

gram Weight
N Newton 1 kg
´
m/sec
2

Force
Nm
m • kgNewton meter
Meter kilogramN
´
m
m
´
kgTorque
Torque
Pa Pascal N/m
2

Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3

Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute — Engine speed

2 - 1
CARACTERISTIQUES GENERALES
SPEC

CARACTERISTIQUES
CARACTERISTIQUES GENERALES
Nom du modèle: TT-R90N
(USA, sauf Californie, CDN, AUS, NZ)
TT-R90NC (Californie)
TT-R90 (Europe)
Numéro de code de modèle: 5HN5 (USA)
5HN6 (Europe, AUS, NZ)
5HN7 (CDN)
Dimensions:
Longueur hors tout 1.525 mm (57,0 in)
Largeur hors tout 605 mm (23,8 in)
Hauteur hors tout 865 mm (34,1 in)
Hauteur de la selle 625 mm (24,6 in)
Empattement 1.040 mm (40,9 in)
Garde au sol minimale 160 mm (6,3 in)
Poids net:
Avec huile et réservoir de carburant rempli 64 kg (141 lb)
Moteur:
Type de moteur 4 temps, refroidissement par air, un arbre à cames en
tête (SOHC)
Disposition du cylindre Monocylindre, incliné vers l’avant
Cylindrée 89 cm
3

(5,43 cu.in)
Alésage
´
course 47,0
´
51,8 mm (1,85
´
2,04 in)
Taux de compression 8,5 : 1
Pression à la compression (standard) 1.000 kPa (10 kg/cm
2

, 145 psi) à 1.000 tr/mn
Système de démarrage Kick
Système de graissage: Carter humide
Type ou grade d’huile:
Huile de moteur (USA et CDN)
A –10 ˚C (10 ˚F) ou plus

Yamalube 4 (10W-30) ou huile moteur SAE 10W-30
de grade SE/SF
A 5 ˚C (40 ˚F) ou plus
õ
Yamalube 4 (20W-40) ou huile moteur SAE 20W-40
de grade SE/SF
(Sauf USA et CDN)
API “SE/SF” ou grade supérieur
0 10 30 50 70 90 110 130
-20 -10 01020
30 40 50

õ
˚F
˚C

2 - 2
CARACTERISTIQUES GENERALES
SPEC

Quantité d’huile:
Huile de moteur
Vidange périodique 0,8 L (0,70 Imp qt, 0,85 US qt)
Quantité totale 1,0 L (0,88 Imp qt, 1,06 US qt)
Filtre à air: Elément de type humide
Carburant:
Type Carburant sans plomb (USA)
Essence super sans plomb (CDN, Europe)
Essence sans plomb uniquement (AUS)
Normal (NZ)
Capacité du réservoir 4,2 L (0,92 Imp gal, 1,11 US gal)
Quantité de la réserve 0,5 L (0,11 Imp gal, 0,13 US gal)
Carburateur:
Type VM16SH
Fabricant MIKUNI
Bougie:
Type CR6HSA/U20FSR-U
Fabricant NGK/DENSO
Ecartement 0,6 à 0,7 mm (0,02 à 0,03 in)
Type d’embrayage: Humide, multidisque et centrifuge automatique
Boîte de vitesses:
Système de réduction primaire Engrenage à denture droite
Taux de réduction primaire 67/18 (3,722)
Système de réduction secondaire Entraînement par chaîne
Taux de réduction secondaire 35/14 (2,500)
Type de boîte de vitesses Prise constante, 3 rapports
Commande Pied gauche
Démultiplication: 1re 37/13 (2,846)
2e 33/19 (1,736)
3e 28/23 (1,217)
Partie cycle:
Type de cadre Double berceau
Angle de chasse 24,83˚
Chasse 56,0 mm (2,2 in)
Pneus:
Type Avec chambre à air
Taille (avant) 2,50-14 4PR
Taille (arrière) 3,00-12 4PR
Fabricant (avant et arrière) CHENG SHIN
Type (avant et arrière) KNOBBY
Pression de gonflage du pneu (avant et arrière) 100 kPa (1,00 kg/cm
2

, 14,5 psi)