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
4 - 40
ENG
REMOVAL POINTS
Rotor
1. Remove:
Rotor nut 1
Washer 2
NOTE:
Loosen the rotor nut while holding the rotor
with sheave holder 3.
Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-1880-A/90890-01701
2. Remove:
Rotor 1
Woodruff key
NOTE:
Use the flywheel puller 2.
Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller:
YU-33270-B/90890-01362
CDI MAGNETO (TT-R90)
4 - 42
ENGCDI MAGNETO AND STARTER CLUTCH (TT-R90E)
REMOVAL POINTS
Rotor
1. Remove:
Rotor nut 1
Washer 2
NOTE:
Loosen the rotor nut while holding the rotor
with sheave holder 3.
Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-1880-A/90890-01701
2. Remove:
Rotor 1
Woodruff key
NOTE:
Use the flywheel puller 2.
Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller:
YU-33270-B/90890-01362
