2006 YAMAHA TTR90 diagram

EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been complied to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.
Bearings
Pitting/damage →
Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 1
is provided for removal and disassembly jobs.
2. Numbers 2
are given in the order of the jobs in the exploded diagram. A number that is
enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol
marks 3
. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4
accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5
is provided in the job instruction chart to save the trouble of an unneces-
sary removal job.
6. For jobs requiring more information, the step-by-step format supplements 6
are given in addi-
tion to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 6 are designed as
thumb tabs to indicate the chapter’s number
and content.
1General information
2Specifications
3Regular inspection and adjustments
4Engine
5Chassis
6Electrical
Illustrated symbols 7 to D are used to identify
the specifications appearing in the text.
7With engine mounted
8Special tool
9Filling fluid
0Lubricant
ATightening
BSpecified value, Service limit
CEngine speed
DResistance (
Ω), Voltage (V), Electric current (A)
Illustrated symbols E to H in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
EApply engine oil
FApply molybdenum disulfide oil
GApply lightweight lithium-soap base grease
HApply molybdenum disulfide grease
Illustrated symbols I to J in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
IApply locking agent (LOCTITE®)
JUse new one 12
34
56
78
90
AB
CD
E
F
G
H
IJ
GEN
INFOSPEC
INSP
ADJ
ENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION ...........................................1-1
MACHINE IDENTIFICATION .....................1-2
IMPORTANT INFORMATION ....................1-3
CHECKING OF CONNECTION .................1-5
SPECIAL TOOLS ......................................1-6
CONTROL FUNCTIONS ............................1-9
FUEL ........................................................1-12
STARTING AND OPERATION ................1-13
CLEANING AND STORAGE ...................1-14
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................2-1
MAINTENANCE SPECIFICATIONS ..........2-4
GENERAL TORQUE
SPECIFICATIONS ...................................2-17
DEFINITION OF UNITS ...........................2-17
CABLE ROUTING DIAGRAM .................2-18
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS ...................3-1
PRE-OPERATION INSPECTION AND
MAINTENANCE .........................................3-3
ENGINE ......................................................3-4
CHASSIS .................................................3-12
ELECTRICAL ...........................................3-23

INHALT
KAPITEL 1
ALLGEMEINES
FAHRZEUGBESCHREIBUNG ..................1-1
FAHRZEUG-IDENTIFIZIERUNG ...............1-2
WICHTIGE INFORMATIONEN ..................1-3
KABELANSCHLÜSSE
KONTROLLIEREN ....................................1-5
SPEZIALWERKZEUGE .............................1-6
BEDIENUNGSELEMENTE UND
DEREN FUNKTION ...................................1-9
KRAFTSTOFF .........................................1-12
ANLASSEN UND INBETRIEBNAHME ...1-13
REINIGUNG UND STILLLEGUNG ..........1-14
KAPITEL 2
TECHNISCHE DATEN
ALLGEMEINE TECHNISCHE DATEN ......2-1
WARTUNGSDATEN ..................................2-4
ALLGEMEINE ANZUGSMOMENTE .......2-17
MASSEINHEITEN ....................................2-17
KABELFÜHRUNGSDIAGRAMME ..........2-18
KAPITEL 3
REGELMÄSSIGE
WARTUNGS- UND
EINSTELLARBEITEN
WARTUNGSINTERVALLE ........................3-1
ROUTINEKONTROLLE VOR
FAHRTBEGINN .........................................3-3
MOTOR ......................................................3-4
FAHRWERK ............................................3-12
ELEKTRISCHE ANLAGE ........................3-23
TABLES DES MATIERES
CHAPITRE 1
RENSEIGNEMENTS
GENERAUX
DESCRIPTION ............................................... 1-1
IDENTIFICATION DE LA MOTO .............. 1-2
INFORMATIONS IMPORTANTES ............ 1-3
VERIFICATION DES CONNEXIONS ........ 1-5
OUTILS SPECIAUX ...................................... 1-6
FONCTIONS DES COMMANDES .............. 1-9
CARBURANT ............................................... 1-12
DEMARRAGE ET
FONCTIONNEMENT .................................. 1-13
NETTOYAGE ET REMISAGE .................. 1-14
CHAPITRE 2
CARACTERISTIQUES
CARACTERISTIQUES GENERALES ........ 2-1
CARACTERISTIQUES D’ENTRETIEN ..... 2-4
CARACTERISTIQUES GENERALES DE
COUPLE ........................................................ 2-17
DEFINITION DES UNITES ........................ 2-17
CHEMINEMENT DES CABLES ................ 2-18
CHAPITRE 3
CONTROLES ET REGLAGES
PERIODIQUES
PROGRAMME D’ENTRETIEN ................... 3-1
CONTROLES ET ENTRETIENS
AVANT UTILISATION ................................. 3-3
MOTEUR ......................................................... 3-4
CHASSIS ........................................................ 3-12
PARTIE ELECTRIQUE .............................. 3-23

CHAPTER 4
ENGINE
CARBURETOR ..........................................4-1
CYLINDER HEAD ......................................4-8
CAMSHAFT AND ROCKER ARMS ........4-13
VALVES AND VALVE SPRINGS ............4-16
CYLINDER AND PISTON ........................4-21
CLUTCH ...................................................4-27
KICK AXLE ..............................................4-33
SHIFT SHAFT ..........................................4-34
OIL PUMP ................................................4-36
CDI MAGNETO (TT-R90) ........................4-39
CDI MAGNETO AND
STARTER CLUTCH (TT-R90E) ...............4-41
CRANKCASE AND CRANKSHAFT ........4-45
SHIFT FORK, SHIFT CAM AND
TRANSMISSION ......................................4-48
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL .......5-1
FRONT FORK ..........................................5-10
HANDLEBAR ...........................................5-13
STEERING ...............................................5-18
SWINGARM .............................................5-20
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM ....................................6-1
IGNITION SYSTEM ....................................6-3
ELECTRIC STARTING SYSTEM
(TT-R90E) ..................................................6-7
CHARGING SYSTEM (TT-R90E) ............6-15
CARBURETOR HEATING SYSTEM .......6-17
MAINTENANCE RECORD ......................6-21

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 - 18
SPEC
KABELFÜHRUNGSDIAGRAMME
TT-R90
1Kurbelgehäuse-Entlüftungsschlauch
2Kabelbaum
3Lichtmaschinen-Kabel
4Chokezug
5Vergaserheizungs-Kabel
6Motorstoppschalter-Kabel
7Thermoschalter
8Thermoschalter-Kabel
9Zündkabel
0Gaszug
ASeilzug-Halterung
BKraftstofftank-Belüftungsschlauch
CBremszug
ÈChokezug, Lichtmaschinen-Kabel, Kabelbaum
und Thermoschalter-Kabel befestigen und dann
Kabelbinder-Ende abschneiden.
ÉDas Zündspulen-Kabel durch die Kabelführung
leiten.
ÊDas Motorstoppschalter-Kabel mit Kunststoffbin-
dern befestigen.
ËDen Bremszug durch die Führungen leiten.
CHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
CHEMINEMENT DES CABLES
TT-R90
1Durit de mise à l’air du carter moteur
2Faisceau de fils
3Fil du volant magnétique CDI
4Câble de starter
5Fil de chauffage du carburateur
6Fil du coupe-circuit du moteur
7Contacteur thermique
8Fil du contacteur thermique
9Fil de bougie
0Câble des gaz
ASupport de câble
BDurit de mise à l’air du réservoir de carburant
CCâble de frein
ÈAprès avoir attaché le câble de starter, le fil du volant
magnétique CDI et le fil du contacteur thermique,
couper la partie excédentaire du collier en plastique.
ÉFaire passer le fil de la bobine d’allumage par le
guide-fil.
ÊAttacher le fil du coupe-circuit du moteur à l’aide de
colliers réutilisables.
ËAcheminer le câble de frein par les guide-câbles.

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