2007 YAMAHA TTR90 steering wheel

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

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.√√
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
U3P281E0.book Page 23 Monday, April 17, 2006 11:26 AM

INDEX
AAccessories and replacement parts ..... 6-16
Air filter element, cleaning .................... 6-10BBattery [TT-R90E(W)] ........................... 6-24
Brake and shift pedals, checking and
lubricating ........................................... 6-21
Brake lever ............................................. 3-2
Brake lever, checking and lubricating ... 6-22
Brake lever free play, adjusting ............ 6-17
Brake pedal ............................................ 3-2
Brake pedal free play, adjusting ........... 6-17
Brake shoes, checking ......................... 6-18CCables, checking and lubricating .......... 6-21
Carburetor, adjusting ............................ 6-13
Care ........................................................ 7-1
Cowling and panel, removing and
installing ............................................... 6-6DDrive chain, cleaning and lubricating .... 6-20
Drive chain slack .................................. 6-18EEngine break-in ...................................... 5-4
Engine idling speed .............................. 6-13
Engine oil ................................................ 6-8
Engine, starting a warm .......................... 5-2
Engine stop switch [TT-R90E(W)] .......... 3-1
Engine stop switch [TT-R90(W)]............. 3-1FFront fork, checking .............................. 6-23
Fuel......................................................... 3-3
Fuel cock ................................................ 3-5
Fuel tank breather hose.......................... 3-4Fuel tank cap........................................... 3-3
Fuse, replacing [TT-R90E(W)] ..............6-26
HHandlebar switches ................................. 3-1IIdentification numbers ............................. 9-1KKey identification number
[TT-R90E(W)]........................................ 9-1
Kickstarter ............................................... 3-6LLabels, location of ...................................1-4MMain switch [TT-R90E(W)] ...................... 3-1
Maintenance and lubrication, periodic..... 6-4
Maintenance, emission control system ... 6-3
Maintenance, periodic ............................. 6-1
Model label .............................................. 9-2PParking [TT-R90E(W)].............................5-5
Parking [TT-R90(W)] ...............................5-4
Part locations .......................................... 2-1
Pre-operation check list........................... 4-2SSafety information ...................................1-1
Seat ......................................................... 3-7
Shifting ....................................................5-3
Shift pedal ............................................... 3-2
Sidestand ................................................ 3-7
Sidestand, checking and lubricating...... 6-22
Spark arrester, cleaning ........................ 6-12
Spark plug, checking ...............................6-7
Specifications .......................................... 8-1
Starter (choke) lever................................ 3-6Starting and warming up a cold engine
[TT-R90E(W)] ....................................... 5-2
Starting and warming up a cold engine
[TT-R90(W)].......................................... 5-1
Starting circuit cut-off system
[TT-R90E(W)] ....................................... 3-8
Start switch [TT-R90E(W)] ...................... 3-1
Steering, checking ................................ 6-23
Storage [TT-R90E(W)] ............................ 7-4
Storage [TT-R90(W)] .............................. 7-3
Supporting the motorcycle .................... 6-26
Swingarm pivots, lubricating ................. 6-22
TThrottle cable free play, adjusting ......... 6-14
Throttle grip and cable, checking
and lubricating .................................... 6-21
Tires ...................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-30
Troubleshooting chart [TT-R90E(W)].... 6-32
Troubleshooting chart [TT-R90(W)] ...... 6-31VValve clearance .................................... 6-14
Vehicle identification number .................. 9-1WWheel bearings, checking..................... 6-24
Wheel (front) ......................................... 6-27
Wheel (rear) .......................................... 6-28
Wheels .................................................. 6-16
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM