2002 YAMAHA TTR90 maintenance

SPEC
2 - 9
Lubrication system:
Oil filter type Wire mesh type ----
Oil pump type Trochoid type ----
Tip clearance “A” or “B” 0.15 mm
(0.0059 in)0.2 mm
(0.0079 in)
Side clearance 0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)0.23 mm
(0.0091 in)
Housing and rotor clearance 0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)0.15 mm
(0.0059 in) 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 70 7.0 50
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:
l1. 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 kW at 20 ˚C (68 ˚F) ----
Spark plug cap:
Type Resin ----
Resistance 10 kW at 20 ˚C (68 ˚F) ----
MAINTENANCE SPECIFICATIONS

3 - 1
INSP
ADJMAINTENANCE 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*1Clean.
* 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