2005 YAMAHA TTR90 oil filter

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

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INSP
ADJ

AIR FILTER CLEANING
1. Install:

Air scoop (right)
1

2. Install:

Air filter case cover
1

3. Clean:

Air filter element
Clean them with solvent.
NOTE:

After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:


Do not twist the element when squeezing
the element.

Leaving too much of solvent in the ele-
ment may result in poor starting.
4. Inspect:

Air filter element
Damage
→
Replace.
5. Apply:

Foam-air-filter oil or engine mixing oil
To the element.
NOTE:

Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:

Air filter element
1

NOTE:

Align the projection
a
on the air filter case with
the hole
b
in the air filter element.
7. Install:

Air filter case cover
8. Install:

Air scoop (right)

INSP
ADJNETTOYAGE DU PARE-ETINCELLES (pour les USA)
FUNKENLÖSCHER REINIGEN (Nur USA)
6. Montieren:
Kipphebeldeckel (Einlaßseite) 1
O-Ringe 2
HINWEIS:
Lithiumfett auf den O-Ring auftragen.
7. Montieren:
Kipphebeldeckel (Auslaßseite)
O-Ringe
Zündkerze
Schwungrad-Abdeckschraube
Kurbelwellenendabdeckung
HINWEIS:
Lithiumfett auf den O-Ring auftragen.
8. Montieren:
Luftfiltergehäuse
Lufthutze (rechts)
FUNKENLÖSCHER REINIGEN (Nur USA)
WARNUNG
Sicherstellen, daß Krümmer und Schall-
dämpfer abgekühlt sind, bevor der Fun-
kenlöscher gereinigt wird.
Motor beim Reinigen der Auspuffanlage
nicht starten.
1. Demontieren:
Schraube (Auspuffendrohr) 1
2. Demontieren:
Auspuffendrohr 2
Das Auspuffendrohr aus dem Schall-
dämpfer ziehen.
3. Reinigen:
Funkenlöscher
Kohlenstoffablagerungen mit einer Draht-
bürste vom Funkenfängerteil an der Innen-
seite des Schalldämpfers 3 entfernen.
Das Auspuffendrohr leicht anklopfen, und
die Kohlenstoffablagerungen vom Außen-
teil a des Auspuffendrohrs entfernen.
4. Montieren:
Auspuffendrohr
Das Auspuffendrohr in den Schall-
dämpfer setzen, und das Schrauben-
loch ausrichten.
Schraube (Auspuffendrohr)
T R..18 Nm (1,8 m · kg, 13 ft · lb)
New
T R..18 Nm (1,8 m · kg, 13 ft · lb)
New
T R..13 Nm (1,3 m · kg, 9,4 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
6. Installer:
Cache de poussoir (côté admission) 1
Joint torque 2
N.B.:
Enduire le joint torique de graisse à base de savon
au lithium.
7. Installer:
Cache de poussoir (côté échappement)
Joint torque
Bougie
Bouchon de distribution
Cache d’extrémit de vilebrequin
N.B.:
Enduire le joint torique de graisse à base de savon
au lithium.
8. Installer:
Boîtier de filtre à air
Carénage de prise d’air (droit)
NETTOYAGE DU PARE-ETINCELLES
(pour les USA)
AVERTISSEMENT
S’assurer que le tuyau et pot d’échappement
sont froids avant d’effectuer le nettoyage du
pare-étincelles.
Ne pas mettre le moteur en marche pendant le
nettoyage du système d’échappement.
1. Déposer:
Boulon (chicane) 1
2. Déposer:
Chicane 2
Sortir la chicane du pot d’échappement.
3. Nettoyer:
Pare-étincelles
Utiliser une brosse à poils métalliques pour
nettoyer les dépôts de calamine de la partie
pare-étincelles de la surface intérieure du
pot d’échappement 3.
Tapoter légèrement la chicane et nettoyer
les dépôts de calamine de la surface exté-
rieure a de la chicane.
4. Installer:
Chicane
Insérer la chicane dans le pot d’échappement
et aligner l’orifice du boulon.
Boulon (chicane)
T R..18 Nm (1,8 m · kg, 13 ft · lb)
New
T R..18 Nm (1,8 m · kg, 13 ft · lb)
New
T R..13 Nm (1,3 m · kg, 9,4 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
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4 - 36
ENGOIL PUMP
OIL PUMP
Extent of removal:1 Oil pump removal2 Oil strainer removal
3 Oil pump disassembly
Extent of removal Order Part name Q’ty Remarks
OIL PUMP REMOVAL AND DIS-
ASSEMBLY
Preparation for removal Clutch housing and clutch carrier Refer to “CLUTCH” section.
Shift shaft Refer to “SHIFT SHAFT” section.
1 Rotary filter 1
2 Oil pump assembly 1
3 Gasket 1
4 Oil pump drive gear 1
5 Oil strainer 1
6 Circlip 1
7 Oil pump driven gear 1
8 Spring washer 1
9 Circlip 1
10 Washer 1
1
2
3

4 - 38
ENGOIL PUMP
INSPECTION
Oil pump
1. Measure:
Tip clearance a
(between the inner rotor 1 and the
outer rotor 2)
Side clearance b
(between the outer rotor 2 and the
rotor housing 3)
Out of specification → Replace the oil
pump assembly.
Rotor housing and rotor clearance c
(between the rotor housing 3 and the
rotors 1 2)
Out of specification → Replace the oil
pump assembly.
Tip clearance a:
0.15 mm (0.0059 in)
: 0.2 mm (0.0079 in)
Side clearance b:
0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)
: 0.23 mm (0.0091 in)
Rotor housing and rotor clear-
ance c:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
: 0.15 mm (0.006 in)
Rotary filter and oil strainer
1. Inspect:
Rotary filter 1
Oil strainer 2
Damage → Replace.
3Upper side
4Lower side
ASSEMBLY AND INSTALLATION
Rotary filter
1. Install:
Rotary filter 1
NOTE:
When installing the rotary filter, align the match
mark a on the rotary filter with the hole b of
the crankshaft.

4 - 45
ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
Extent of removal Order Part name Q’ty Remarks
CRANKCASE SEPARATION
AND CRANKSHAFT REMOVAL
Preparation for removal Seat, fuel tank and rear fender
Exhaust pipe
Air filter case
Carburetor Refer to “CARBURETOR” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Engine guard and drive sprocket
Engine assembly From the chassis.
Cylinder head Refer to “CYLINDER HEAD” section.
Cylinder and piston Refer to “CYLINDER AND PISTON” sec-
tion.
Clutch housing and clutch carrier Refer to “CLUTCH” section.
Kick axle assembly Refer to “KICK AXLE” section.