2002 YAMAHA TTR90 oil

4 - 36
ENGOIL PUMP
OIL PUMP
Extent of removal:1 Oil pump removal2 Oil strainer removal
3 Oil pump disassembly
Extent of removal Order Part name Q’ty Remarks
OIL PUMP REMOVAL AND DIS-
ASSEMBLY
Preparation for removal Clutch housing and clutch carrier Refer to “CLUTCH” section.
Shift shaft Refer to “SHIFT SHAFT” section.
1 Rotary filter 1
2 Oil pump assembly 1
3 Gasket 1
4 Oil pump drive gear 1
5 Oil strainer 1
6 Circlip 1
7 Oil pump driven gear 1
8 Spring washer 1
9 Circlip 1
10 Washer 1
1
2
3

4 - 37
ENGOIL PUMP
Extent of removal Order Part name Q’ty Remarks
11 Oil pump cover 1
12 Dowel pin 2
13 Oil pump drive shaft 1
14 Pin 1
15 Inner rotor 1
16 Outer rotor 1
17 Rotor housing 1
3

4 - 38
ENGOIL PUMP
INSPECTION
Oil pump
1. Measure:
lTip clearance a
(between the inner rotor 1 and the
outer rotor 2)
lSide clearance b
(between the outer rotor 2 and the
rotor housing 3)
Out of specification ® Replace the oil
pump assembly.
lRotor housing and rotor clearance c
(between the rotor housing 3 and the
rotors 1 2)
Out of specification ® Replace the oil
pump assembly.
Tip clearance a:
0.15 mm (0.0059 in)
: 0.2 mm (0.0079 in)
Side clearance b:
0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)
: 0.23 mm (0.0091 in)
Rotor housing and rotor clear-
ance c:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
: 0.15 mm (0.006 in)
Rotary filter and oil strainer
1. Inspect:
lRotary filter 1
lOil strainer 2
Damage ® Replace.
3Upper side
4Lower side
ASSEMBLY AND INSTALLATION
Rotary filter
1. Install:
lRotary filter 1
NOTE:
When installing the rotary filter, align the match
mark a on the rotary filter with the hole b of
the crankshaft.

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ENGCDI MAGNETO
CDI MAGNETO
Extent of removal:1 Pickup coil/stator assembly removal2 Rotor removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO AND STATOR
REMOVAL
Preparation for removal Fuel tank
Crankcase cover (left) Refer to “CLUTCH” section.
1 CDI magneto coupler 1
2 Pickup coil/stator assembly 1
3 Rotor nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 4 Rotor 1
5 Woodruff key 1
1
2

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ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
Extent of removal Order Part name Q’ty Remarks
CRANKCASE SEPARATION
AND CRANKSHAFT REMOVAL
Preparation for removal Seat, fuel tank and rear fender
Exhaust pipe
Air filter case
Carburetor Refer to “CARBURETOR” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Engine guard and drive sprocket
Engine assembly From the chassis.
Cylinder head Refer to “CYLINDER HEAD” section.
Cylinder and piston Refer to “CYLINDER AND PISTON” sec-
tion.
Clutch housing and clutch carrier Refer to “CLUTCH” section.
Kick axle assembly Refer to “KICK AXLE” section.

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ENGCRANKCASE AND CRANKSHAFT
Extent of removal:1 Timing chain removal2 Crankcase separation
3 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
Shift shaft Refer to “SHIFT SHAFT” section.
Oil pump and oil strainer Refer to “OIL PUMP” section.
Rotor Refer to “CDI MAGNETO” section.
1 Timing chain guide (intake) 1
2 Timing chain 1
3 Crankcase (right) 1
4 Dowel pin 2
5 Crankshaft 1
6 Crankcase (left) 1
1
2
3

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ENGCRANKCASE AND CRANKSHAFT
INSPECTION
Crankshaft
1. Measure:
lRunout limit a
lConnecting rod big end side clearance
b
lConnecting rod big end radial clear-
ance c
lCrank width d
Out of specification ® Replace.
Use the dial gauge and a thickness
gauge.
Standard Limit
Runout
limit—0.03 mm
(0.0012 in)
Side
clearance0.10 ~ 0.40 mm
(0.0039 ~ 0.0157 in)—
Radial
clearance0.010 ~ 0.025 mm
(0.0004 ~ 0.0010 in)0.05 mm
(0.002 in)
Crack
width42.95 ~ 43.00 mm
(1.691 ~ 1.693 in)—
ASSEMBLY AND INSTALLATION
Crankcase
1. Apply:
lSealant
On the crankcase (left).
NOTE:
lClean the contacting surface of crankcase
(left and right) before applying the sealant.
lDO NOT ALLOW any sealant to come in
contact with the oil gallery a.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505

5 - 1
CHAS
EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL AND FRONT BRAKE
FRONT WHEEL AND REAR WHEEL
Extent of removal:1 Front wheel removal2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
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”.
2
31
3
5