2002 YAMAHA TTR90 light

3 - 18
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

3 - 19
INSP
ADJ
ELECTRICAL/SPARK PLUG INSPECTION
EC370000
ELECTRICAL
EC371001
SPARK PLUG INSPECTION
1. Remove:
lSpark plug
2. Inspect:
lElectrode 1
Wear/damage ® Replace.
lInsulator color 2
Normal condition is a medium to light
tan color.
Distinctly different color ® Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure:
lPlug gap a
Use a wire gauge or thickness gauge.
Out of specification ® Regap.
4. Clean the plug with a spark plug cleaner
if necessary.
Spark plug gap:
0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Standard spark plug:
CR6HSA (NGK)
U20FSR-U (DENSO)
5. Tighten:
lSpark plug
NOTE:
lBefore installing a spark plug, clean the gas-
ket surface and plug surface.
lFinger-tighten a the spark plug before
torquing to specification b.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)

4 - 6
ENGCARBURETOR
EC464600
Float
1. Inspect:
lFloat 1
Damage ® Replace.
ASSEMBLY AND INSTALLATION
Carburetor
1. Install:
lPilot air screw 1
Note the following installation points:
lScrew in the pilot air screw until it is lightly
seated.
lBack out it by the specified number of
turns.
Pilot air screw:
1-3/4 turns out
2. Install:
lThrottle valve 1
lStarter plunger 2
NOTE:
Align the slit a of the throttle valve with the tab
b of the carburetor top.
FUEL LEVEL ADJUSTMENT
WARNING
Gasoline (fuel) and its vapors are highly
flammable and explosive. Keep away from
sparks, cigarettes, flames or other sources
of ignition.

4 - 19
ENGVALVES AND VALVE SPRINGS
2. Lap:
lValve face
lValve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps:
lApply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
lApply molybdenum disulfide oil to the
valve stem.
lInstall the valve into the cylinder head.
lTurn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
lApply a fine lapping compound to the
valve face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.
lApply Mechanic’s blueing dye (Dykem) to
the valve face.
lInstall the valve into the cylinder head.
lPress the valve through the valve guide
and onto the valve seat to make a clear
pattern.
lMeasure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.

4 - 20
ENGVALVES AND VALVE SPRINGS
ASSEMBLY AND INSTALLATION
1. Apply:
lMolybdenum disulfide oil
(onto the valve stem and valve stem
seal)
2. Install:
lValve stem seats
lValves
lValve springs
lValve spring retainers
NOTE:
lMake sure that each valve is installed in its
original place, also referring to the embossed
mark as follows.
Intake: “G”
Exhaust: “L”
lInstall the valve springs with the larger pitch
a facing upwards.
bSmaller pitch
New
3. Install:
lValve cotters
NOTE:
While compressing the valve spring with a
valve spring compressor and attachment 1
install the valve cotters.
Valve spring compressor:
YM-4019/90890-04019
4. To secure the valve cotters onto the
valve stem, lightly tap the valve tip with a
piece of wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.

4 - 32
ENGCLUTCH
ASSEMBLY AND INSTALLATION
Primary clutch
1. Install:
lWasher 1
lNut (primary clutch) 2
NOTE:
Tighten the nut while holding the magneto
rotor with the sheave holder 3.
Clutch
1. Install:
lLock washer 1
lNut (clutch boss) 2
NOTE:
Use the clutch holding tool 3 to hold the clutch
boss.
For USA and CDN
õExcept for USA and CDN
2. Bend:
lLock washer tab
Sheave holder:
YS-1880-A/90890-01701
Clutch holding tool:
YM-91042/90890-04086
T R..50 Nm (5.0 m · kg, 36 ft · lb)
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)

Clutch release adjustment
1. Adjust:
lClutch release
Adjustment steps:
lLoosen the locknut 1.
lTurn in the adjuster 2 until it is lightly
seated.
lTurn out by 1/8 turn.
lTighten the locknut.
T R..
Locknut:
8 Nm (0.8 m • kg, 5.8 ft • lb)

4 - 40
ENGCDI MAGNETO
REMOVAL POINTS
Rotor
1. Remove:
lRotor nut 1
lWasher 2
NOTE:
lLoosen the rotor nut while holding the rotor
with sheave holder 3.
lDo not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-1880-A/90890-01701
2. Remove:
lRotor 1
lWoodruff key
NOTE:
lUse the flywheel puller 2.
lCenter the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller:
YU-33270-B/90890-01362

4 - 46
ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION
EC4H3000
REMOVAL POINTS
Shift fork, shift cam and transmission
1. Remove:
lShift forks
lShift cam
lDrive axle assembly
lMain axle assembly
NOTE:
lTap lightly on the transmission drive axle and
shift cam with a soft hammer to remove.
lRemove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
ASSEMBLY AND INSTALLATION
Transmission, shift cam shift fork
1. Install:
lMain axle assembly 1
lDrive axle assembly 2
2. Install:
lShift fork 1 “L” 1
lShift fork 2 “R” 2
lShift cam 3
lGuide bar 4
NOTE:
The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “L”.
3. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.