2002 YAMAHA TTR90 oil

5 - 5
CHAS
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
AUSBAU
Radlager (nach Bedarf)
1. Demontieren:
lLager 1
HINWEIS:
Die Lager mit einem Lageraustreiber 2 aus-
bauen.
PRÜFUNG
Rad
1. Messen:
lFelgenschlag
Unvorschriftsmäßig ® Instand setzen/
Erneuern.
Max. Felgenschlag
Höhenschlag 1 2,0 mm
Seitenschlag 2 2,0 mm
Bremsbeläge
1. Kontrollieren:
lTrommelbremsbelag
Glasige Oberfläche ® Anschleifen.
grobes Sandpapier verwenden.
HINWEIS:
Nach dem Anschleifen die Schleifpartikel mit
einem Lappen abwischen.
2. Messen:
lTrommelbremsbelag-Stärke
Unvorschriftsmäßig ® Erneuern.
HINWEIS:
Die Bremsbeläge und Federn als Satz erset-
zen, wenn eines der Teile bis zum Grenzwert
verschlissen ist.
Trommelbremsbelag-Stärke a
Standard
vorne: 3,0 mm
hinten: 4,0 mm
Grenzwert
2,0 mm
POINTS DE DEPOSE
Roulement de roue (si nécessaire)
1. Déposer:
lRoulement 1
N.B.:
Déposer le roulement en utilisant un arrache-roule-
ment courant 2.
CONTROLE
Roue
1. Mesure:
lVoile de roue
Hors limite ® Réparer/changer.
Limite de voile de la roue:
Radial 1: 2,0 mm (0,08 in)
Latéral 2: 2,0 mm (0,08 in)
Garnitures de frein
1. Examiner:
lSurface de garniture de mâchoire de frein
Zones brillantes ® Poncer.
Utiliser du papier de verre à gros grains.
N.B.:
Après ce ponçage, éliminer les particules avec un
chiffon.
2. Mesurer:
lEpaisseur de garniture de mâchoire de frein
Hors spécifications ® Remplacer.
N.B.:
Remplacer les deux mâchoires de frein et ressorts si
l'une d'elles est usée à la limite.
Epaisseur de garniture de mâchoire
de frein a:
Standard:
avant: 3,0 mm (0,12 in)
arrière: 4,0 mm (0,16 in)
Limite:
2,0 mm (0,08 in)

5 - 7
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
Preparation for disas-
semblyDrain the fork oil.
1Adjuster 1
2Fork spring 1
3Dust cover 1
4Stopper ring 1
5Bolt (damper rod) 1 Use special tool.
Refer to “REMOVAL POINTS”.
6Inner tube 1
7Damper rod 1
8Oil seal 1
9Outer tube 1
1
2

5 - 8
CHASFRONT FORK
REMOVAL POINTS
Inner tube
1. Remove:
lBolt (damper rod)
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2, loosen the bolt
(damper rod).
Damper rod holder:
YM-1300/90890-01294
T-handle:
YM-1326/90890-01326
EC555000
ASSEMBLY AND INSTALLATION
Front fork assembly
1. Install:
lOil seal 1
NOTE:
Press the oil seal into the outer tube with fork
seal driver weight 2 and fork seal driver
attachment 3.
2. Fill:
lFork oil
3. After filling up, slowly pump the fork up
and down to distribute the fork oil.
Fork seal driver weight:
YM-33963/90890-01184
Fork seal driver attachment:
90890-01186
Oil quantity:
64 cm3 (2.26 Imp oz, 2.16 US oz)
Recommended oil:
Fork oil 15W or equivalent

6 - 1
–+ELECELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1CDI magneto
2CDI unit
3Ignition coil
4Spark plug
5“ENGINE STOP” switch
6Thermo switch
7Carburetor heater
8Rectifier/regulatorCOLOR CODE
B...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
W..................... White
EC612000
WIRING DIAGRAM
G/WB/RW/LW/RBr G
RW
WB
Y/R
O
BO
B
B
BY/RY
WY/RB
W
Y
B
GG/W
B/W
B/W
BrB/RWWWY
OO
BBW/LY/RR
W
B
B
B
W/R
Y/R
OFF
RUN
B
Y/R
B
B
Y
Y
1
23
4
5 6
7 8
B/R ................... Black/Red
B/W .................. Black/White
G/W.................. Green/White
W/L .................. White/Blue
W/R .................. White/Red
6

–+ELEC
6 - 2
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
NOTE:
lRemove the following parts before inspection.
1) Seat
2) Fuel tank
lUse the following special tools in this inspection.
Spark gap testClean or replace
spark plug.
Check entire ignition
system for connection.Repair or replace.
Check “ENGINE STOP”
switch.Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check CDI magneto. Pickup coil Replace.
Source coil Replace.
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754Pocket tester:
YU-3112-C/90890-03112
No Spark
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good

6 - 4
–+ELECIGNITION SYSTEM
EC626002
IGNITION COIL INSPECTION
1. Inspect:
lPrimary coil resistance
Out of specification ® Replace.
Tester (+) lead ® Orange lead 1
Tester (–) lead ® Black lead 2
Primary coil
resistanceTester selector
position
0.18 ~ 0.28 W at
20 ˚C (68 ˚F)W ´ 1
2. Inspect:
lSecondary coil resistance
Out of specification ® Replace.
NOTE:
When inspecting the secondary coil resis-
tance, remove the spark plug cap.
CDI MAGNETO INSPECTION
1. Inspect:
lPickup coil resistance
Out of specification ® Replace. Tester (+) lead ® Spark plug lead 1
Tester (–) lead ® Orange lead 2
Secondary coil
resistanceTester selector
position
6.3 ~ 9.5 kW at
20 ˚C (68 ˚F)kW ´ 1
Tester (+) lead ® Red lead 1
Tester (–) lead ® White lead 2
Pickup coil
resistanceTester selector
position
248 ~ 372 W at
20 ˚C (68 ˚F)W ´ 100

6 - 5
–+ELECIGNITION SYSTEM
2. Inspect:
lSource coil resistance
Out of specification ® Replace.
Tester (+) lead ® Brown lead 1
Tester (–) lead ® Green lead 2
Source coil
resistanceTester selector
position
688 ~ 1,032 W
at 20 ˚C (68 ˚F)W ´ 100

–+ELEC
6 - 6
CARBURETOR HEATING SYSTEM
CARBURETOR HEATING SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning carburetor heating system.
NOTE:
lRemove the following parts before inspection.
1) Seat
2) Fuel tank
lUse the following special tools in this inspection.
Check entire carburetor
heating system for connec-
tion.Repair or replace.
Check thermo switch. Replace.
Check carburetor heater. Replace.
Check CDI magneto. Source coil Replace.
Replace rectifier/regulator.
Pocket tester:
YU-3112-C/90890-03112
OK
OK
OK
No good
No good
No good
No good
OK