2006 YAMAHA TTR90 warning

5 - 3
CHASFRONT WHEEL AND REAR WHEEL
REAR WHEEL AND REAR BRAKE
Extent of removal:
1 Rear wheel removal
2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Brake rod 1
2Cotter pin 1
3 Nut (tension bar) 1
4 Bolt (tension bar) 1
5 Wheel axle nut 1
6 Rear wheel axle 1
7 Drive chain puller 2
8 Rear wheel 1
9 Collar (right) 1
10 Brake shoe plate assembly 1
2
1
3

5 - 6
CHAS
ASSEMBLY AND INSTALLATION
1. Install:
Brake camshaft lever 1
NOTE:
Install the brake camshaft lever in relation to
the punch mark a as shown.
ÈFront
ÉRear
1
1a
È
a 1
1
É
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
Springs 1
Brake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New
FRONT WHEEL AND REAR WHEEL

5 - 10
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Brake cable holder 1
2 Cap bolt 1
3 Adjuster 1 Only loosening.
4 Pinch bolt (under bracket) 1 Only loosening.
5 Front fork 1
1

5 - 15
CHAS
REMOVAL POINTS
Handlebar grip
1. Remove:
Handlebar grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
INSPECTION
Handlebar
1. Inspect:
Handlebar 1
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
ASSEMBLY AND INSTALLATION
Handlebar
1. Install:
Handlebar 1
NOTE:
Align the punched mark a on the handlebar
with the upper surface of the handlebar holder
on the upper bracket.
HANDLEBAR

5 - 16
CHASHANDLEBAR
2. Install:
Grip (left) 1
Apply the adhesive to the handlebar 2.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.
Install the grip (left) to the handlebar so that
the line b between the two arrow marks
faces straight upward.
3. Install:
Grip (right) 1
Collar 2
Apply the adhesive on the tube guide 3.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the tube guide surface a
with a lacquer thinner.
Align the mating mark b on the grip (right)
with the slot c in the tube guide.
cb
4. Install:
Screws (throttle housing)
WARNING
After tightening the screws, check that the
throttle grip
1 moves smoothly. If it does
not, retighten the bolts for adjustment.

5 - 18
CHASSTEERING
EC560000
STEERING
LS
LS
T R..TIGHTENING STEPS:
Tighten ring nut.
38 Nm (3.8 m  kg, 27 ft  Ib)
Loosen it completely.
Retighten it.
1 Nm (0.1 m  kg, 0.7 ft  Ib)
T R..40 Nm (4.0 m  kg, 29 ft  Ib)
5 9681076 43
21
Extent of removal:
1 Under bracket removal
2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front fork Refer to “FRONT FORK” section.
1 Steering stem bolt 1
2 Handle crown 1
3 Ring nut 1 Use special tool.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
4 Ball race cover 1
5 Under bracket 1
6 Bearing inner race 2
7 Upper bearing ball 19
8 Lower bearing ball 16
9 Dust seal 1
10 Bearing outer race 2
2
1

5 - 19
CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long rod
2 and the hammer.
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
STEERING

5 - 20
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:
1 Swingarm removal
2 Rear shock absorber removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Rear fender
Drive chain
1Cotter pin 2
2Pin 2
3 Rear shock absorber 1
4 Pivot shaft 1 Hold the swingarm.
5 Swing arm 1
6 Drive chain guide 1
7 Drive chain guard 1
8 Drive chain support 1
2
1