2004 YAMAHA TTR90 engine

SPEC
2 - 17
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg × m/sec
2 Force
Nm
m • kgNewton meter
Meter kilogramN × m
m × kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute—Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

2 - 18
SPEC

CABLE ROUTING DIAGRAM
TT-R90
1
Crankcase breather hose
2
Wire harness
3
CDI magneto lead
4
Starter cable
5
Carburetor heating lead
6
Engine stop switch lead
7
Thermo switch
8
Thermo switch lead
9
Spark plug lead
0
Throttle cable
A
Cable holder
B
Fuel tank breather hose
C
Brake cable
Å
After fastening the starter cable, CDI magneto lead, wire harness and
thermo switch lead, cut off any excess from the plastic locking tie end.
ı
Pass the ignition coil lead through the lead guide.
Ç
Fasten the engine stop switch lead with the plastic bands.
Î
Pass the brake cable through the cable guides.
12345
9
0
B A
6
C 1Å
ı
Ç
Î
Î
A
A
67
8
20 ~ 30 mm
(0.79 ~ 1.18 in)

CABLE ROUTING DIAGRAM

2 - 19
SPEC

1
Cable guide
2
Brake cable
3
Throttle cable
4
Fuel tank breather hose
5
Engine stop switch lead
6
Air vent hose
7
Air intake duct
8
Ignition coil
9
Cable guide
0
Wire harness
A
Damper
B
CDI unit lead
C
CDI unit
D
Rectifier/regulator lead
E
Rectifier/regulator
F
Crankcase breather hose
G
Carburetor breather hose
H
Spark plug lead
I
Fuel hose
J
Starter cable
K
CDI magneto lead
L
Thermo switch
A
123
4
5
6
7
8
9
0A
C
E B
F G H I
6
6 J L
5
H
B8 K
7 ÅÇ
‰
Ç
Ï
Ì
B - B C - C
D - DF - FE
ı
Î
D
D
B
D
A A B
B B
B
C
C C
CE
B D
B
D
F F F F

CABLE ROUTING DIAGRAM

2 - 20
SPEC

Å
Pass the fuel tank breather hose through the
cable guide.
ı
Pass the throttle cable and engine stop switch
lead through the cable guide.
Ç
Pass the air vent hose through the hose guide.
Î
Fasten the CDI unit lead and rectifier/regulator
lead with the plastic clamp.
‰Align the tape on the rectifier/regulator lead with
the plastic clamp.
ÏAfter fastening the engine stop switch lead, cut
off any excess from the plastic locking tie end.ÌPass the CDI unit lead through the lead guide.
A
123
4
5
6
7
8
9
0A
C
E B
F G H I
6
6 J L
5
H
B8 K
7 ÅÇ
‰
Ç
Ï
Ì
B - B C - C
D - DF - FE
ı
Î
D
D
B
D
A A B
B B
B
C
C C
CE
B D
B
D
F F F F
CABLE ROUTING DIAGRAM

2 - 21
SPECCABLE ROUTING DIAGRAM
TT-R90E
1Crankcase breather hose
2CDI magneto lead
3Wire harness
4Thermo switch
5Thermo switch lead
6CDI unit lead
7Spark plug lead
8Starter cable
9Starter relay lead
0Starter motor leadAStarter motor
BThrottle cable
CBrake cable
DEngine stop switch lead
EMain switch lead
FStart switch lead
ÅPass the spark plug lead
through the lead guide.ıMake sure that the starter cable
does not contact the engine
bracket.
ÇFasten the engine stop lead with
the plastic bands.
ÎPass the brake cable through
the cable guide.
‰Fasten the start switch lead with
the plastic bands.
30 ~ 40 mm
(1.18 ~ 1.57 in)A
B
40 ~ 50 mm
(1.57 ~ 1.97 in)
1
B
C
D
E ‰
F
ÎÎÇ A875 4
6 3
2
1
Å
ı
A
B
0
9
10 ~ 20 mm
(0.39 ~ 0.79 in)

2 - 22
SPECCABLE ROUTING DIAGRAM
1Clamp
2Engine stop switch lead
3Main switch lead
4Start switch lead
5Brake cable
6Throttle cable
7Fuel tank breather hose
8Ignition coil
9Wire harness
0Starter relay
AStarter motor leadBCrankcase breather hose
CStarter motor lead
DNeutral switch lead
ECDI magneto lead
FCDI unit
GFuel overflow hose
HSpark plug lead
IFuel hose
JCarburetor heater lead
KCarburetor breather hose
LCarburetor heater couplerMCDI magneto coupler
NCDI unit coupler
OCDI unit connector
PCDI unit lead
QThermo switch lead
RThermo switch
SStarting circuit cut-off relay
TStarting circuit cut-off relay lead
URectifier/regulator lead
VRectifier/regulator
WStarter relay lead
A AA
C C
D
B
B B
BF FF
EE
D
A - AB - BE - E
C
F - FG - GD
KK
QRÔ
8
E
H
˜ 2 3 4
6
5
4
3
2
1
J
I
H
G
F
E
D
CBA 0 Ï 9 8 Î K 7
S
W U
V
A
0
Í T
99
QP
PT
9 
Ò
ˆ Ø
Ç ı
Å
Ó
Œ
Â
E
GGA
P
O
NML 9
È
9
Ì
Ê
◊
25 mm (1.0 in)
∏
‰
35 ~ 45 mm
(1.38 ~ 1.77 in)
30 ~ 40 mm
(1.18 ~ 1.57 in)
Ë

2 - 23
SPECCABLE ROUTING DIAGRAM
ÅPass the start switch lead, main
switch lead, engine stop switch
lead and throttle cable through
the cable guide.
ıPass the fuel tank breather hose
through the hose guide.
ÇPass the carburetor breather
hose through the hose guide.
ÎFasten the carburetor heater lead,
main switch lead, engine stop
switch lead and start switch lead.‰After fastening the CDI mag-
neto lead, cut off any excess
from the plastic locking tie end.
ÏFasten the battery leads to the
bracket with the plastic locking
tie. For fastening, pass the plas-
tic locking tie through the hole in
the bracket.
ÌAfter fastening the starter motor
lead, cut off any excess from the
plastic locking tie end.ÓAfter fastening the CDI mag-
neto lead, cut off any excess
from the plastic locking tie end.
ÈPosition the start switch coupler
and engine stop switch coupler
between the carburetor breather
hose and thermo switch.
ÔMake sure that the CDI unit lead
does not contact the thermo
switch bracket.
A AA
C C
D
B
B B
BF FF
EE
D
A - AB - BE - E
C
F - FG - GD
KK
QRÔ
8
E
H
˜ 2 3 4
6
5
4
3
2
1
J
I
H
G
F
E
D
CBA 0 Ï 9 8 Î K 7
S
W U
V
A
0
Í T
99
QP
PT
9 
Ò
ˆ Ø
Ç ı
Å
Ó
Œ
Â
E
GGA
P
O
NML 9
È
9
Ì
Ê
◊
25 mm (1.0 in)
∏
‰
35 ~ 45 mm
(1.38 ~ 1.77 in)
30 ~ 40 mm
(1.18 ~ 1.57 in)
Ë

2 - 24
SPEC
Fasten the starter cable, thermo
switch lead, CDI unit lead, main
switch lead, start switch lead
and engine stop switch lead.
ÒFasten the wire harness, CDI
unit leads, thermo switch lead
and CDI magneto lead.
˜Pass the carburetor heater lead
between the carburetor breather
hose and air intake duct.ˆPosition the main switch cou-
pler between the carburetor
breather hose and air intake
duct.
ØFasten the start switch lead,
main switch lead and engine
stop switch lead at the tape with
the plastic locking tie.
∏Fasten the battery leads.ŒFasten the wire harness and
starting circuit cut-off relay lead
at the tape for the wire harness
with the plastic locking tie.
ÂFasten the rectifier/regulator
lead and starter relay leads. For
fastening, pass the plastic lock-
ing tie through the hole in the
battery box.
A AA
C C
D
B
B B
BF FF
EE
D
A - AB - BE - E
C
F - FG - GD
KK
QRÔ
8
E
H
˜ 2 3 4
6
5
4
3
2
1
J
I
H
G
F
E
D
CBA 0 Ï 9 8 Î K 7
S
W U
V
A
0
Í T
99
QP
PT
9 
Ò
ˆ Ø
Ç ı
Å
Ó
Œ
Â
E
GGA
P
O
NML 9
È
9
Ì
Ê
◊
25 mm (1.0 in)
∏
‰
35 ~ 45 mm
(1.38 ~ 1.77 in)
30 ~ 40 mm
(1.18 ~ 1.57 in)
Ë
CABLE ROUTING DIAGRAM