2006 YAMAHA TTR90 brake

2 - 18
SPECCABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
TT-R90
1Crankcase breather hose
2Wire harness
3CDI magneto lead
4Starter cable
5Carburetor heating lead
6Engine stop switch lead
7Thermo switch
8Thermo switch lead
9Spark plug lead0Throttle cable
ACable holder
BFuel tank breather hose
CBrake cable
ÈAfter fastening the starter cable, CDI magneto lead, wire harness and
thermo switch lead, cut off any excess from the plastic locking tie end.
ÉPass the ignition coil lead through the lead guide.
ÊFasten the engine stop switch lead with the plastic bands.
ËPass the brake cable through the cable guides.
12345
9
0
B A
6
CÈ
É
Ê
Ë
Ë
67
8
20 ~ 30 mm
(0.79 ~ 1.18 in)

2 - 19
SPECCABLE ROUTING DIAGRAM
1Cable guide
2Brake cable
3Throttle cable
4Fuel tank breather hose
5Engine stop switch lead
6Air vent hose
7Air intake duct
8Ignition coil
9Cable guide
0Wire harness
ADamperBCDI unit lead
CCDI unit
DRectifier/regulator lead
ERectifier/regulator
FCrankcase breather hose
GCarburetor breather hose
HSpark plug lead
IFuel hose
JStarter cable
KCDI magneto lead
LThermo switch
A
123
4
5
6
7
8
9
0A
C
E B
F G H I
6
6 J L
5
H
B8
F K
7 ÈÊ
Ì
Ê
Í
ÎB - B C - C
D - DF - FE
É
Ë
D
D
B
D
A A B
B B
B
C
C C
CE
B D
B
D
F F F F

2 - 21
SPECCABLE ROUTING DIAGRAM
TT-R90E
1Crankcase breather hose
2CDI magneto lead
3Wire harness
4Thermo switch
5Thermo switch lead
6CDI unit lead
7Spark plug lead
8Starter cable
9Starter relay lead
0Starter motor leadAStarter motor
BThrottle cable
CBrake cable
DEngine stop switch lead
EMain switch lead
FStart switch lead
ÈPass the spark plug lead
through the lead guide.ÉMake sure that the starter
cable does not contact the
engine bracket.
ÊFasten the engine stop lead
with the plastic bands.
ËPass the brake cable through
the cable guide.
ÌFasten the start switch lead
with the plastic bands.
30 ~ 40 mm
(1.18 ~ 1.57 in)
A
20 ~30 mm
(0.79 ~ 1.18 in)B
C
D
E Ì
F
ËËÊ A875 4
6 3
2
1
È
É
A
0
9
10 ~ 20 mm
(0.39 ~ 0.79 in)

2 - 22
SPECCABLE ROUTING DIAGRAM
1Clamp
2Engine stop switch lead
3Main switch lead
4Start switch lead
5Brake cable
6Throttle cable
7Fuel tank breather hose
8Ignition coil
9Wire harness
0Starter relay
AStarter motor leadBCrankcase breather hose
CStarter motor lead
DNeutral switch lead
ECDI magneto lead
FCDI unit
GFuel overflow hose
HSpark plug lead
IFuel hose
JCarburetor heater lead
KCarburetor breather hose
LCarburetor heater couplerMCDI magneto coupler
NCDI unit coupler
OCDI unit connector
PCDI unit lead
QThermo switch lead
RThermo switch
SStarting circuit cut-off relay
TStarting circuit cut-off relay lead
URectifier/regulator lead
VRectifier/regulator
WStarter relay lead
A AA
C C
D
B
B B
BF FF
EE
D
A - AB - BE - E
C
F - FG - GD
KK
QRÑ
8
E
H
Ô 2 3 4
6
5
4
3
2
1
J
I
H
G
F
E
D
CBA 0 Í 9 8 Ë K 7
S
W U
V
A
0
Ú T
99
QP
PT
9 Ò
Ó
Õ Ö
Ê É
È
Ï
Ø
Ù
E
GGA
P
O
NML 9
Ð
9
Î
Û
Ý
25 mm (1.0 in)
×
Ì
35 ~ 45 mm
(1.38 ~ 1.77 in)
30 ~ 40 mm
(1.18 ~ 1.57 in)
Ü

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
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.
NOTE:
From 18 months or 210 hours, repeat the maintenance intervals starting from 6 months or
90 hours.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No. ITEMCHECKS AND
MAINTENANCE JOBSWHICH-
EVER
COMES
FIRSTINITIAL EVERY
month 1 6 12
hours 30 90 150
1 * Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.√
√
2 Spark plugCheck condition.
Adjust gap and clean.√
√
3 * Valve clearanceCheck and adjust valve clearance when engine is
cold.√
4 * Air filter elementClean with solvent.
Replace if necessary.√
√
5 * Breather systemCheck ventilation hose for cracks or damage.
Replace if necessary.√
√
√
6 * CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.√
√
√
7 Exhaust systemCheck for leakage.
Tighten if necessary.
Replace gasket if necessary.√
√
8 Engine oil Change (warm engine before draining).
√
√
√
9 ClutchCheck operation.
Adjust or replace cable.√
√
√
10 * Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes
if necessary.√
√
√
11 * Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes
if necessary.√
√
√
12 * WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√
√
√
13 * TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√
√
14 * Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√
√
15 * SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap based grease.√
√
√
16 Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain.Every ride
3

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
17 * Steering bearingsCheck bearing assemblies for looseness.
Lubricate with lithium soap based grease every or
120 hours or 12 months (whichever comes first).√
√
18Brake and clutch
lever pivot shaftsApply lithium soap based grease lightly.
√
√
√
19Brake pedal pivot
shaftApply lithium soap based grease lightly.
√
√
√
20 Sidestand pivotCheck operation.
Apply lithium soap based grease lightly.√
√
21 * Front forkCheck operation and for oil leakage.
Replace if necessary.√
√
22 *Shock absorber
assemblyCheck operation and for oil leakage.
Replace if necessary.√
√
23 * Control cablesApply Yamaha chain and cable lube or engine oil
10W-30 thoroughly.√
√
√
24 *Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√
√
√
25 * Chassis fastenersCheck all chassis fitting and fasteners.
Correct if necessary.√
√
√
26Battery (TT-R90E
only)Check terminal for looseness and corrosion.
√ No. ITEMCHECKS AND
MAINTENANCE JOBSWHICH-
EVER
COMES
FIRSTINITIAL EVERY
month 1 6 12
hours 30 90 150


3

3 - 3
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condi-
tion.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Brake Check operation/adjustment. P3-12
Engine oil Change oil as required. P3-6 ~ 8
Drive chain Check alignment/adjustment/lubrication. P3-13 ~ 15
Spark plug Check color/condition. P3-23
Throttle Check for proper throttle cable operation. P3-4
Air filter Foam type – must be clean and damp oil always P3-4 ~ 5
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P3-17 ~ 20
Fittings/fasteners Check all – tighten as necessary. P2-13

3 - 12
INSP
ADJCHASSIS/FRONT BRAKE ADJUSTMENT/
REAR BRAKE ADJUSTMENT
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever free play a
Out of specification → Adjust.
Free play (brake lever):
10 ~ 20 mm (0.39 ~ 0.79 in)
(at brake lever end)
a
21
2. Adjust:
Brake lever free play
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal free play a
Out of specification → Adjust.
2. Adjust:
Brake pedal free play Adjustment steps:
Loosen the locknuts 1.
Turn the adjusters 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 locknuts.
CAUTION:
Make sure that there is no brake drag
after adjusting the front brake lever free
play.
Free play:
10 ~ 20 mm (0.39 ~ 0.79 in)
Adjustment steps:
Turn the adjuster 1 in or out until the
specified free play is obtained.
Turning in → Free play is decreased.
Turning out → Free play is increased.
CAUTION:
Make sure that the brake does not drag
after adjusting it.
1
a