2005 YAMAHA TTR90 key

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of six chapters;
“General Information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis” and “Electrical”.
2. The table of contents is at the beginning
of the manual. Look over the general lay-
out of the book before finding then
required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.
WARNING
CAUTION:

1 - 2
GEN
INFO

MACHINE IDENTIFICATION
EC120001
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the
number to your Yamaha dealer for posi-
tive identification of the model you own.
2. If your machine is stolen, the authorities
will need the number to search for and
identify your machine.
KEY IDENTIFICATION NUMBER (TT-R90E)
The key identification number
1
is stamped
on the key as shown in the following illustra-
tion. This number can be used for ordering a
new key.
EC121001
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number
1 is
stamped on the right of the steering head pipe.
1
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into
the elevated part of the left-side of the engine.
EC124000
MODEL LABEL
The model label 1 is affixed to the frame
under the rider’s seat. This information will be
needed to order spare parts.
1

1 - 9
GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
MAIN SWITCH (TT-R90E)
Functions of the respective switch positions
are as follows:
ON: The engine can be started only at this
position.
OFF: All electrical circuits are switched off.
The key can be removed in this position.
“ENGINE STOP” SWITCH
Make sure that the engine stop switch 1 is
positioned to “”. The engine stop switch has
been equipped to ensure safety in an emer-
gency such when the machine is up set or
trouble takes place in the throttle system. The
engine will not start or run when the engine
stop switch is turned to “”.
START SWITCH (TT-R90E)
The start switch 1 is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
1
SHIFT PEDAL
The gear ratios of the constant-mesh 3 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
WARNING
When starting out on the machine, shift the
transmission into 1st after pulling in the front
brake lever and closing the throttle grip.

3 - 3
INSP
ADJ

ENGINE/THROTTLE CABLE ADJUSTMENT/
AIR FILTER CLEANING
EC350000
ENGINE
THROTTLE CABLE ADJUSTMENT
1. Check:

Throttle grip free play
a

Out of specification
→
Adjust.
Throttle grip free play
a
:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:

Throttle grip free play
AIR FILTER CLEANING
NOTE:

Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid

wear and possible engine damage.Throttle grip free play adjustment steps:
NOTE:

Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.

Loosen the locknut
1
on throttle cable.

Turn the adjuster
2
in or out until the
specified free play is obtained.
Turning in: Free play is increased.
Turning out: Free play is decreased.

Tighten the locknut.
WARNING

After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.

4 - 39
ENG
CDI MAGNETO (TT-R90)
Extent of removal:1 Pickup coil/stator assembly removal2 Rotor removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO AND STATOR
REMOVAL
Preparation for removal Fuel tank
Crankcase cover (left) Refer to “CLUTCH” section.
1 CDI magneto coupler 1
2 Pickup coil/stator assembly 1
3 Rotor nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 4 Rotor 1
5 Woodruff key 1
1
2
CDI MAGNETO (TT-R90)

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 - 41
ENGCDI MAGNETO AND STARTER CLUTCH (TT-R90E)
CDI MAGNETO AND STARTER CLUTCH (TT-R90E)
Extent of removal:1 Pickup coil/stator removal2 Rotor removal
3 Starter clutch/wheel gear removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO AND STATOR
REMOVAL
Preparation for removal Fuel tank
Crankcase cover (left) Refer to “CLUTCH” section.
1 CDI magneto coupler 1
2 Pickup coil/stator assembly 1
3 Rotor nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 4 Rotor 1
5 Woodruff key 1
6 Shaft 1
7 Idler gear 1
8 Starter clutch/wheel gear 1/1
1
2
3

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