2004 YAMAHA TTR90 oil pressure

SPEC

2 - 1
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: TT-R90S (USA, CDN, AUS, NZ)
TT-R90 (Europe, ZA)
TT-R90ES (USA, CDN, AUS, NZ)
TT-R90E (Europe, ZA)
Model code number: TT-R90:
5HNH (USA)
5HNJ (Europe, AUS, NZ, ZA)
5HNK (CDN)
TT-R90E:
5HNL (USA)
5HNM (Europe, AUS, NZ, ZA)
5HNN (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 (TT-R90) 64 kg (141 lb)
(TT-R90E) 67 kg (147.7 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 (TT-R90) Kick starter
(TT-R90E) Kick and electric starter
Lubrication system: Wet sump
GENERAL SPECIFICATIONS

SPEC

2 - 3 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 Steel tube backbone
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)
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 95 mm (3.74 in)
Electrical:
Ignition system CDI
Generator system (TT-R90E) CDI magneto
Battery type (TT-R90E) GT4B-5
Battery voltage/capacity (TT-R90E) 12 V/2.5 AH
Specific gravity (TT-R90E) 1.350
GENERAL 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) (TT-R90) M6
×
1.0 8 7 0.7 5.1
(TT-R90E) M6
×
1.0 8 10 1.0 7.2
Drive sprocket cover M6
×
1.0 2 7 0.7 5.1
Crankcase cover (right) (TT-R90) M6
×
1.0 9 7 0.7 5.1
(TT-R90E) 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 (TT-R90E) 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 (TT-R90E) 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

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS/
PERIODIC MAINTENANCE AND LUBRICATION
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
PERIODIC MAINTENANCE AND LUBRICATION
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
* Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
* ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace if necessary.
* CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
* Front brakeCheck operation.
Adjust brake lever free play and replace brake
shoes if necessary.Every ride
* Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
* WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
* TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
* Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
* SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap base grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
* Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.
3

3 - 2
INSP
ADJ

PRE-OPERATION INSPECTION AND MAINTENANCE
*: Since these items requires special tools data and technical skills, they should be serviced.
*
1

: For USA
SERVICE NOTES:

No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every
0.5 ~ 1.0 hour. If unit is subjected to extremely hard usage and wet weather riding, chain
must be checked constantly. See “Lubrication Intervals” for additional details.
No. 2. AIR FILTER: Remove and clean filter every 20 ~ 40 hours.
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
* Chassis fastenersMake sure that all nuts, bolts and screws are
properly tightened.
Tighten if necessary.
SidestandCheck operation.
Lubricate and repair if necessary.
* Spark arrester
*
1

Clean.
* Front forkCheck operation and for oil leakage.
Correct accordingly.
*Rear shock
absorber assemblyCheck operation and shock absorber for oil
leakage.
Replace shock absorber assembly if necessary.
Battery
(TT-R90E only)Check terminal for corrosion.
Clean if necessary.
Item Routine Page
Brake Check operation/adjustment. P3-11
Engine oil Change oil as required. P3-5 ~ 7
Drive chain Check alignment/adjustment/lubrication. P3-12 ~ 13
Spark plug Check color/condition. P3-20
Throttle Check for proper throttle cable operation. P3-3
Air filter Foam type – must be clean and damp oil always P3-3 ~ 4
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P3-14 ~ 15
Fittings/fasteners Check all – tighten as necessary. P2-13 Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
3