2002 YAMAHA TTR90 drain bolt

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

3 - 6
INSP
ADJ
ENGINE OIL REPLACEMENT
(Except for USA and CDN)
CAUTION:
lDo not add any chemical additives or use
oils with a grade of CD a or higher.
lDo not use oils labeled “ENERGY CON-
SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
lDo not allow foreign materials to enter the
crankcase.
5. Install:
lDipstick
6. Start the engine and let it warm up for
several minutes.
7. Turn off the engine and inspect the oil
level once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
ENGINE OIL REPLACEMENT
1. Start the engine and warm it up for sev-
eral minutes and wait for five minutes.
2. Place the machine on a level place and
hold it on upright position by placing the
suitable stand under the engine.
3. Place a suitable container under the
engine.
4. Remove:
lDipstick 1
lDrain bolt (with gasket) 2
Drain the crankcase of its oil.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SE/SF” or higher grade
(Designed primarily for motor-
cycles)
a
b

3 - 7
INSP
ADJ
PILOT AIR SCREW ADJUSTMENT
5. Install:
lGasket
lDrain bolt
New
T R..20 Nm (2.0 m · kg, 14 ft · lb)
6. Fill:
lCrankcase
Oil quantity:
Periodic oil change:
0.8 L (0.70 Imp qt, 0.85 US qt)
7. Install:
lDipstick
8. Inspect:
lEngine (for oil leaks)
lOil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION”.
PILOT AIR SCREW ADJUSTMENT
1. Adjust:
lPilot air screw 1
Adjusting steps:
lScrew in the pilot air screw until it is lightly
seated.
lBack out by the specified number of turns.
Pilot air screw:
1-3/4 turns out

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