2007 YAMAHA TTR90 maintenance

INTRODUCTION
EAU41660
Congratulations on your purchase of the Yamaha TT-R90(W)/TT-R90E(W). This model is the result of Yamaha’s vast expe-
rience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of crafts-
manship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at
the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the
motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
AN IMPORTANT SAFETY MESSAGE:

READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR MOTORCYCLE. MAKE SURE YOU UNDER-
STAND ALL INSTRUCTIONS.


PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.


NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.


WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg (88 lb).
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn-
ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to
operate the motorcycle safely.
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERA-
TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:


OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE
OPERATION.
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INTRODUCTION

OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.


OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.


OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
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TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch [TT-R90E(W)] ..............3-1
Handlebar switches ........................3-1
Shift pedal .......................................3-2
Brake lever .....................................3-2
Brake pedal ....................................3-2
Fuel tank cap ..................................3-3
Fuel .................................................3-3
Fuel tank breather hose ..................3-4
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Kickstarter .......................................3-6
Seat ................................................3-7
Sidestand ........................................3-7
Starting circuit cut-off system
[TT-R90E(W)] ...............................3-8
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a
cold engine [TT-R90(W)] ............. 5-1
Starting and warming up a
cold engine [TT-R90E(W)] ........... 5-2
Starting a warm engine .................. 5-2
Shifting ........................................... 5-3
Engine break-in .............................. 5-4
Parking [TT-R90(W)] ....................... 5-4
Parking [TT-R90E(W)]..................... 5-5
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for
the emission control system ....... 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing the
cowling and panel ....................... 6-6
Checking the spark plug ................. 6-7
Engine oil ....................................... 6-8
Cleaning the air filter element ...... 6-10
Cleaning the spark arrester .......... 6-12
Adjusting the carburetor ............... 6-13
Adjusting the engine idling
speed ........................................ 6-13
Adjusting the throttle cable
free play .................................... 6-14Valve clearance ........................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-16
Accessories and replacement
parts ......................................... 6-16
Adjusting the brake lever
free play .................................... 6-17
Adjusting the brake pedal
free play .................................... 6-17
Checking the front and rear
brake shoes .............................. 6-18
Drive chain slack .......................... 6-18
Cleaning and lubricating the
drive chain ................................ 6-20
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-21
Checking and lubricating the
brake and shift pedals .............. 6-21
Checking and lubricating the
brake lever ................................ 6-22
Checking and lubricating the
sidestand .................................. 6-22
Lubricating the swingarm
pivots ........................................ 6-22
Checking the front fork ................. 6-23
Checking the steering .................. 6-23
Checking the wheel bearings ....... 6-24
Battery [TT-R90E(W)] ................... 6-24U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3 [(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premi-
um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance cost.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if ethanol content
does not exceed 10%. Gasohol con-
taining methanol is not recommended
by Yamaha because it can cause dam-
age to the fuel system or vehicle perfor-
mance problems.
For Europe, Oceania and South Afri-
ca
CAUTION:
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13411
Fuel tank breather hose TT-R90(W)
TT-R90E(W)
Before operating the motorcycle:

Check the fuel tank breather hose
connection.
Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
For Oceania and South Africa: UN-
LEADED GASOLINE ONLY
Fuel tank capacity:
4.2 L (1.11 US gal) (0.92 Imp.gal)
Fuel reserve amount:
0.5 L (0.13 US gal) (0.11 Imp.gal)
1. Fuel tank breather hose
1. Fuel tank breather hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17231
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the follow-
ing pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU40350
PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE
OF YOUR VEHICLE IS IMPORTANT
IN ORDER TO ENJOY LONG, PLEA-
SURABLE SERVICE. ESPECIALLY
IMPORTANT ARE THE MAINTE-
NANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER EN-
GINE OPERATION AND MAXIMUM
PERFORMANCE. IN THE FOLLOW-
ING PERIODIC MAINTENANCE
CHARTS, THE SERVICES RELATED
TO EMISSIONS CONTROL ARE
GROUPED SEPARATELY. THESE
SERVICES REQUIRE SPECIALIZED
DATA, KNOWLEDGE, AND EQUIP-
MENT. YAMAHA DEALERS ARE
TRAINED AND EQUIPPED TO PER-
FORM THESE PARTICULAR SER-
VICES.
WARNING
EWA10340
Modifications not approved by
Yamaha may cause loss of perfor-
mance, excessive emissions, andrender the vehicle unsafe for use.
Consult a Yamaha dealer before at-
tempting any changes.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17310
Owner’s tool kit The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10340
Modifications not approved by
Yamaha may cause loss of perfor-
mance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before at-tempting any changes.U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU39943
Periodic maintenance chart for the emission control system NOTE:

From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
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*Crankcase breather sys-
temCheck ventilation hose for cracks or damage and drain
any deposits.
Replace if necessary.√√√
6*CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.√√√
7 Exhaust systemCheck for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.√√
8 Engine oilChange (warm engine before draining).√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU35346
General maintenance and lubrication chart No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
1*ClutchCheck operation.
Adjust if necessary.√√√
2*Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes if
necessary.√√√
3*Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes if
necessary.√√√
4*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√
5*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√
6*Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√√
7*Swingarm pivot bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
8 Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly.Every ride
9*Steering bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
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