2003 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 4.1 L (0.90 Imp gal, 1.08 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 kgf/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
Generator system CDI magneto
Battery type GT4B-5
Battery voltage/capacity 12 V/2.5 AH
Specific gravity 1.350
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)12.980 mm
(0.511 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 10 1.0 7.2
Drive sprocket cover M6
×
1.0 2 7 0.7 5.1
Crankcase cover (right) M6
×
1.0 9 10 1.0 7.2
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
Starter clutch and rotor M6
×
1.0 3 14 1.4 10
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
Neutral switch M10
×
1.25 1 18 1.8 13
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 Imp 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/YAMAHA ----
Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C (68 ˚F)
(Brown – Green)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(Red – White)----
CDI unit-model/manufacturer 5HN/YAMAHA ----
Ignition coil:
Model/manufacturer 2JN-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 ˚C (68 ˚F) ----
Spark plug cap:
Type Resin ----
Resistance 10 kΩ at 20 ˚C (68 ˚F) ----
Charging system:
System type CDI magneto ----
Model/manufacturer F5HN/YAMAHA ----
Normal output 14 V/100 W at 5,000 r/min ----
Lighting coil 1 resistance (color) 0.64 ~ 0.96 Ω at 20 ˚C (68 ˚F)
(White – Black)----
Lighting coil 2 resistance (color) 0.52 ~ 0.78 Ω at 20 ˚C (68 ˚F)
(Yellow – Black)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH620B-12/SHINDENGEN ----
No-load regulated voltage 14.0 ~ 15.0 V ----
Rectifier capacity 8 A ----
Electric starting system:
Type Constant mesh
Starter motor:
Model/manufacturer 5HN/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.018 ~ 0.022 Ω at 20 ˚C (68 ˚F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Brush quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)3.92 N
(400g,
14.1 oz)
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in) ----
MAINTENANCE SPECIFICATIONS

SPEC
2 - 15
Starter relay:
Model/manufacturer MS5F-751/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ---- Item Standard Limit
MAINTENANCE SPECIFICATIONS