2006 YAMAHA TTR90 maintenance

SPEC
2 - 16 Starter relay:
Model/manufacturer MS5F-751/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 °C (68 °F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 °C (68 °F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ---- Item Standard Limit
MAINTENANCE SPECIFICATIONS

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 - 4
INSP
ADJENGINE/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.

–+ELEC
6 - 21
MAINTENANCE RECORD
MAINTENANCE RECORD
Copies of work orders and/or receipts for parts you purchase and install will be required to docu-
ment maintenance done in accordance with the emission warranty. The chart below is printed only
as a reminder to you that the maintenance work is required. It is not acceptable proof of mainte-
nance work.
MAINTE-
NANCE
INTERVALDATE OF
SERVICEMILEAGESERVICING DEALER
NAME AND ADDRESSREMARKS
1 Month
6 Months
12 Months
18 Months
24 Months
30 Months
36 Months
42 Months
48 Months
54 Months
60 Months
66 Months