2002 YAMAHA TTR90 engine oil

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols
1
to
6
are designed as
thumb tabs to indicate the chapter’s number
and content.
1
General information
2
Specifications
3
Regular inspection and adjustments
4
Engine
5
Chassis
6
Electrical
Illustrated symbols
7
to
D
are used to identify
the specifications appearing in the text.
7
With engine mounted
8
Special tool
9
Filling fluid
0
Lubricant
A
Tightening
B
Specified value, Service limit
C
Engine speed
DResistance (W), Voltage (V), Electric current (A)
Illustrated symbols E to H in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
EApply engine oil
FApply molybdenum disulfide oil
GApply lightweight lithium-soap base grease
HApply molybdenum disulfide grease
Illustrated symbols I to J in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
IApply locking agent (LOCTITE®)
JUse new one 12
34
56
78
90
AB
CD
E F
G H
IJ
GEN
INFOSPEC
INSP
ADJENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

CHAPTER 4
ENGINE
CARBURETOR ......................................... 4-1
CYLINDER HEAD ..................................... 4-8
CAMSHAFT AND ROCKER ARMS ....... 4-13
VALVES AND VALVE SPRINGS ........... 4-16
CYLINDER AND PISTON ....................... 4-21
CLUTCH .................................................. 4-27
KICK AXLE ............................................. 4-33
SHIFT SHAFT ......................................... 4-34
OIL PUMP ............................................... 4-36
CDI MAGNETO ....................................... 4-39
CRANKCASE AND CRANKSHAFT ....... 4-41
SHIFT FORK, SHIFT CAM AND
TRANSMISSION ..................................... 4-44
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL ...... 5-1
FRONT FORK ........................................... 5-6
HANDLEBAR ............................................ 5-9
STEERING .............................................. 5-10
SWINGARM ............................................ 5-11
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM ................................... 6-1
IGNITION SYSTEM ................................... 6-2
CARBURETOR HEATING SYSTEM ........ 6-6
MAINTENANCE RECORD ....................... 6-9

1 - 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are
removed. Lock tab(s) should be bent
along the bolt or nut flat(s) after the bolt
or nut has been properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.

1 - 6
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
lFor U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-” or “ACC-”.
lFor others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1083-A
90890-01084
90890-01085Slide hammer set
Weight
Slide hammer bolt
These tools are used when removing or installing the
rocker arm shafts.YU-1083-A 90890-01084
90890-01085
YU-1268, 90890-01268 Ring nut wrench
This tool is used when loosen the steering ring nut to
specification.YU-1268 90890-01268
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YU-8036-B
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-B 90890-03113
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-1300
90890-01294Damper rod holder set
Damper rod holder
Use this tool to remove and install the damper rod.YM-1300 90890-01294
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.YU-1304 90890-01304

1 - 12
GEN
INFO
STARTING AND OPERATION
STARTING AND OPERATION
CAUTION:
Prior to operating the machine, perform
steps listed in pre-operation check list.
WARNING
Never start your engine or let it run for any
length of time in a closed area. The exhaust
fumes are poisonous and can cause loss of
consciousness and death within a short
time. Always operate your machine in an
area with adequate ventilation.
STARTING A COLD ENGINE
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
1. Turn the fuel cock to “ON”.
2. Operate the starter (choke) and com-
pletely close the throttle grip.
3. Slide the “ENGINE STOP” switch to the
“”.
4. Kick the kick starter with full strength to
start the engine.
5. After the engine starts, warm up for one
or two minutes. Make sure the stater
(choke) is returned to the original position
before riding.
STARTING A WARM ENGINE
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke)
should not be used. The throttle should be
opened slightly.
CAUTION:
See “Engine break-in Section” prior to
operating engine for the first time.WARMING UP
To get maximum engine life, always “warm-up”
the engine before starting off. Never acceler-
ate hard with a cold engine! To see whether or
not the engine is warm, see if it responds to
throttle normally with the stater (choke) turned
off.
WARNING
Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.
ENGINE BREAK-IN
Brake-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially
of slack cables and drive chain and loose
spokes.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.

SPEC
2 - 1
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: TT-R90P
(USA-except for California, CDN, AUS, NZ, ZA)
TT-R90PC (USA for California)
TT-R90 (Europe)
Model code number: 5HN8 (USA)
5HN9 (Europe, AUS, NZ, ZA)
5HNA (CDN)
Dimensions:
Overall length 1,525 mm (57.0 in)
Overall width 605 mm (23.8 in)
Overall height 865 mm (34.1 in)
Seat height 625 mm (24.6 in)
Wheelbase 1,040 mm (40.9 in)
Minimum ground clearance 160 mm (6.3 in)
Basic weight:
With oil and full fuel tank 64 kg (141 lb)
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 89 cm
3 (5.43 cu.in)
Bore ´ stroke 47.0 ´ 51.8 mm (1.85 ´ 2.04 in)
Compression ratio 8.5 : 1
Compression pressure (STD) 1,000 kPa (10 kg/cm
2, 145 psi) at 1,000 r/min
Starting system Kick starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
(For USA and CDN)
At –10 ˚C (10 ˚F) or higher
Yamalube 4 (10W-30) or SAE 10W-30 type
SE/SF motor oil
At 5 ˚C (40 ˚F) or higher õ
Yamalube 4 (20W-40) or SAE 20W-40 type
SE/SF motor oil
(Except for USA and CDN)
API “SE/SF” or higher grade
0 10 30 50 70 90 110 130
-20 -10 01020
30 40 50

õ
˚F
˚C
GENERAL SPECIFICATIONS
2

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

2 - 16
SPECCABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1Crankcase breather hose
2Wire harness
3CDI magneto lead
4Starter cable
5Carburetor heating lead
6Engine stop switch lead
7Thermo switch
8Thermo switch lead
9Spark plug lead
0Throttle cableACable holder
BFuel tank breather hose
CBrake cable
After fastening the starter cable, CDI magneto lead, wire harness and
thermo switch lead, cut off any excess from the plastic locking tie end.
õPass the ignition coil lead through the lead guide.
‚Fasten the engine stop switch lead with the plastic bands.
ëPass the brake cable through the cable guides.
12345
9
0
B A
6
C 1
õ
‚
ë
ë
A
A
67
8
20 ~ 30 mm
(0.79 ~ 1.18 in)