2002 YAMAHA TTR90 oil

SPEC
2 - 2
Oil capacity:
Engine oil
Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet type element
Fuel:
Type Unleaded gasoline only (USA, AUS and NZ)
Regular unleaded gasoline only (CDN, Europe)
Regular gasoline (ZA)
Tank capacity 4.2 L (0.92 lmp gal, 1.11 US gal)
Reserve amount 0.5 L (0.11 Imp gal, 0.13 US gal)
Carburetor:
Type VM16SH
Manufacturer MIKUNI
Spark plug:
Type CR6HSA/U20FSR-U
Manufacturer NGK/DENSO
Gap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Clutch type: Wet, multiple-disc and centrifugal automatic
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 35/14 (2.500)
Transmission type Constant mesh, 3-speed
Operation Left foot operation
Gear ratio: 1st 37/13 (2.846)
2nd 33/19 (1.736)
3rd 28/23 (1.217)
Chassis:
Frame type Double cradle
Caster angle 24.83˚
Trail 56.0 mm (2.2 in)
Tire:
Type With tube
Size (front) 2.50-14 4PR
Size (rear) 3.00-12 4PR
Manufacturer (front and rear) CHENG SHIN
Type (front and rear) KNOBBY
Tire pressure (front and rear) 100 kPa (1.00 kg/cm
2, 14.5 psi)
GENERAL SPECIFICATIONS
2

SPEC
2 - 3
Brake:
Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 110 mm (4.33 in)
Rear wheel travel 93 mm (3.66 in)
Electrical:
Ignition system CDI magneto
GENERAL SPECIFICATIONS

SPEC
2 - 7
Piston:
Piston to cylinder clearance 0.025 ~ 0.045 mm
(0.0010 ~ 0.0018 in)0.15 mm
(0.0059 in)
Piston size “D” 46.960 ~ 46.975 mm
(1.8488 ~ 1.8494 in)----
Piston over size (2nd) 47.5 mm (1.8701 in) ----
(4th) 48.0 mm (1.8898 in) ----
Measuring point “H” 4 mm (0.16 in) ----
Piston off-set 0.75 mm (0.0295 in) ----
Piston pin bore inside diameter 13.002 ~ 13.013 mm
(0.5119 ~ 0.5123 in)13.045 mm
(0.5136 in)
Piston pin outside diameter 12.996 ~ 13.000 mm
(0.5117 ~ 0.5118 in)12.976 mm
(0.5109 in)
Piston rings:
Top ring
Type Barrel ----
Dimensions (B ´ T) 1.0 ´ 2.0 mm (0.04 ´ 0.08 in) ----
End gap (installed) 0.10 ~ 0.25 mm
(0.004 ~ 0.010 in)0.4 mm
(0.016 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring
Type Taper ----
Dimensions (B ´ T) 1.0 ´ 2.0 mm (0.04 ´ 0.08 in) ----
End gap (installed) 0.10 ~ 0.25 mm
(0.004 ~ 0.010 in)0.4 mm
(0.016 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring
Dimensions (B ´ T) 2.0 ´ 2.3 mm (0.08 ´ 0.09 in) ----
End gap (installed) 0.2 ~ 0.7 mm (0.01 ~ 0.03 in) ----Item Standard Limit
H
D
T
B
B
T
B
T
MAINTENANCE SPECIFICATIONS

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 - 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

2 - 4
CARACTERISTIQUES D’ENTRETIENSPEC
CARACTERISTIQUES D’ENTRETIEN
MOTEUR
Désignation Standard Limite
Culasse:
Limite de déformation ---- 0,03 mm
(0,0012 in)
Cylindre:
Alésage 47,000 à 47,005 mm
(1,8504 à 1,8506 in)47,05 mm
(1,8524 in)
Limite d’ovalisation ---- 0,05 mm
(0,0020 in)
Arbre à cames:
Méthode d’entraînement Transmission par chaîne
(côté gauche)----
Dimensions de came
Admission “A” 25,428 à 25,528 mm
(1,0011 à 1,0050 in)25,328 mm
(0,9972 in)
“B” 21,034 à 21,134 mm
(0,8281 à 0,8320 in)20,934 mm
(0,8242 in)
Echappement “A” 25,286 à 25,386 mm
(0,9955 à 0,9994 in)25,186 mm
(0,9916 in)
“B” 21,047 à 21,147 mm
(0,8286 à 0,8326 in)20,947 mm
(0,8247 in)
Limite de voile d’arbre à cames ---- 0,03 mm
(0,0012 in)