OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG TT-R90(W) TT-R90E(W) 3P2-28199-81
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ AUF RECYCLINGPAPIER GEDRUCKT PRINTED IN JAPAN 2006.04-0.
U3P281E0.
U3P281E0.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM INTRODUCTION EAU41660 Congratulations on your purchase of the Yamaha TT-R90(W)/TT-R90E(W). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship 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.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM 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.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM IMPORTANT MANUAL INFORMATION EAU41090 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM IMPORTANT MANUAL INFORMATION EWA14350 WARNING THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MOTORCYCLE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW. THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MOTORCYCLE.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM IMPORTANT MANUAL INFORMATION EAU10200 TT-R90(W)/TT-R90E(W) OWNER’S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, March 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM TABLE OF CONTENTS SAFETY 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 ..........
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM TABLE OF CONTENTS Replacing the fuse [TT-R90E(W)].............................6-26 Supporting the motorcycle ............6-26 Front wheel ...................................6-27 Rear wheel ...................................6-28 Troubleshooting ............................6-30 Troubleshooting chart [TT-R90(W)] ...............................6-31 Troubleshooting chart [TT-R90E(W)].............................6-32 MOTORCYCLE CARE AND STORAGE ..............
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM SAFETY INFORMATION EAU41860 Safe riding ● 1 ● ● ● ● Always make pre-operation checks. Careful checks may help prevent an accident. This motorcycle is designed for offroad use only, therefore, it is illegal to operate it on public streets, roads, or highways, even a dirt or gravel one. Off-road use on public lands may be illegal. Please check local regulations before riding. This motorcycle is designed to carry the operator only. No passengers.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM SAFETY INFORMATION Loading and accessories Adding accessories to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding accessories to your motorcycle. Use extra care when riding a motorcycle that has added accessories.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM SAFETY INFORMATION 1 Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area.
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM SAFETY INFORMATION EAU41370 Location of important labels Please read the following important labels carefully before operating this vehicle.
U3P281E0.book Page 5 Monday, April 17, 2006 11:26 AM SAFETY INFORMATION For Canada 1 1 2 TIRE INFOMATION INFORMATION SUR LES PNEUS La pression des pneus à froid doit normalement être réglée comme suit. AVANT : 100kPa, {1.00kgf/cm2}, 15psi ARRIERE : 100kPa, {1.00kgf/cm2}, 15psi Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm2}, 15psi REAR : 100kPa, {1.
U3P281E0.
U3P281E0.book Page 7 Monday, April 17, 2006 11:26 AM SAFETY INFORMATION Except for Canada 1 1 2 TIRE INFORMATION Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm2}, 15psi REAR : 100kPa, {1.00kgf/cm2}, 15psi YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN 3RV-21668-A0 YAMAHA 3 4GB-2155A-00 4 Before you operate this vehicle, read the owner’s manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant d’utiliser ce véhicule.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS EAU40340 Main switch [TT-R90E(W)] EAU12346 Handlebar switches Left EAU41890 Engine stop switch “ / ” [TT-R90(W)] Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine. EAU12660 3 The main switch controls the ignition system. The main switch positions are described below. 1.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS EAU39850 Shift pedal EAU12890 Brake lever EAU12941 Brake pedal 3 1. Shift pedal 1. Brake lever 1. Brake pedal This motorcycle is equipped with a constant-mesh 3-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position. The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13180 Fuel tank cap EAU13211 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU41930 3 For Canada 1. Fuel tank cap To remove the fuel tank cap, turn it counterclockwise, and then pull it off. To install the fuel tank cap, insert it into the tank opening, and then turn it clockwise. 1. Fuel tank filler tube 2.
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS [(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 premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance cost. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%.
U3P281E0.book Page 5 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS ● ● Check the fuel tank breather hose for cracks or damage, and replace it if damaged. Make sure that the end of the fuel tank breather hose is not blocked, and clean it if necessary. EAU13561 Fuel cock ON The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF 3 1.
U3P281E0.book Page 6 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! EAU13590 Starter (choke) lever “ ” EAU13680 Kickstarter 3 1. Starter (choke) lever “ ” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
U3P281E0.book Page 7 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS EAU41600 EAU37490 Seat Sidestand To remove the seat Remove the nuts, and then pull the seat off. The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. EWA14190 WARNING 3 1. Projection 2. Seat holder 2. Place the seat in the original position, and then tighten the nuts. 1. Nut To install the seat 1.
U3P281E0.book Page 8 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS EAU41610 Starting circuit cut-off system [TT-R90E(W)] The starting circuit cut-off system prevents starting when the transmission is in gear. Periodically check the operation of the starting circuit cut-off system according to the following procedure. 3 EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding.
U3P281E0.book Page 9 Monday, April 17, 2006 11:26 AM INSTRUMENT AND CONTROL FUNCTIONS 3 With the engine turned off: 1. Make sure that the engine stop switch is set to “ 2. Turn the key to “ON”. 3. Shift the transmission into gear. 4. Keep the front or rear brake applied. 5. Push the start switch. Does the engine start? NO NOTE: This check is most reliable if performed with a warmed-up engine. ”. The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM PRE-OPERATION CHECKS EAU15605 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-3 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-8 Front brake • • • • Rear brake • Check operation. • Check pedal free play. • Adjust if necessary.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Brake pedal • Make sure that operation is smooth. • Lubricate pedal pivoting point if necessary. 6-21 Brake lever • Make sure that operation is smooth. • Lubricate lever pivoting point if necessary. 6-22 Sidestand • Make sure that operation is smooth. • Lubricate pivot if necessary. 6-22 Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM OPERATION AND IMPORTANT RIDING POINTS EAU41680 EWA14620 WARNING ● 5 ● ● This model is designed for offroad use only. Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM OPERATION AND IMPORTANT RIDING POINTS EAU40090 Starting and warming up a cold engine [TT-R90E(W)] 1. Turn the fuel cock lever to “ON”. 2. Turn the key to “ON” and make sure that the engine stop switch is set to “ ”. 3. Shift the transmission into the neutral position. EWA14410 WARNING ● ● Be sure to shift the transmission into neutral before starting the engine. Never ride with the sidestand down.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM OPERATION AND IMPORTANT RIDING POINTS EAU39901 Shifting ECA15441 CAUTION: ● 5 1. Shift pedal 2. Neutral position This motorcycle has a 3-speed transmission with a centrifugal, automatic clutch. Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM OPERATION AND IMPORTANT RIDING POINTS EAU39920 Engine break-in There is never a more important period in the life of your engine than the first 5 hours of riding. It is also important to accustom the rider to the motorcycle during this time. Please read the following information carefully. Since the engine is brand new, do not put an excessive load on it for the first 5 hours of operation.
U3P281E0.book Page 5 Monday, April 17, 2006 11:26 AM OPERATION AND IMPORTANT RIDING POINTS EAU17170 Parking [TT-R90E(W)] When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10310 WARNING ● 5 ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU40350 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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 technical skills. INITIAL No.
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU35346 General maintenance and lubrication chart INITIAL No. 6 ITEM CHECKS AND MAINTENANCE JOBS ODOMETER READINGS 1000 km (600 mi) or 1 month or 30 hours 3000 km (1800 mi) or 6 months or 90 hours 5000 km (3000 mi) or 12 months or 150 hours 1 * Clutch • Check operation. • Adjust if necessary. √ √ √ 2 * Front brake • Check operation.
U3P281E0.book Page 5 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM CHECKS AND MAINTENANCE JOBS ODOMETER READINGS 1000 km (600 mi) or 1 month or 30 hours 3000 km (1800 mi) or 6 months or 90 hours 5000 km (3000 mi) or 12 months or 150 hours √ √ √ 10 * Chassis fasteners • Check all chassis fitting and fasteners. • Correct if necessary. 11 Brake lever pivot shaft • Apply lithium-soap-based grease (all-purpose grease) lightly.
U3P281E0.book Page 6 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18740 EAU19193 Removing and installing the cowling and panel Panel A To remove the panel Remove the bolts, and then take the panel off. 1. Bolt 2. Cowling A 1. Panel A 2. Cowling A 6 The cowling and panel shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.
U3P281E0.book Page 7 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. EAU19603 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.
U3P281E0.book Page 8 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.
U3P281E0.book Page 9 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR To change the engine oil 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 5. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. 7.
U3P281E0.book Page 10 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU41632 EWA10430 Cleaning the air filter element WARNING The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. To clean the air filter element 1. Remove panel A. (See page 6-6.) 2. Remove the air filter case cover by removing the screws.
U3P281E0.book Page 11 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. If dirt or water is visible, remove the hoses, clean them, and then reinstall them. 1 ECA15571 CAUTION: ● ● Make sure that the mesh and the sponge material are properly seated in the air filter case. The engine should never be operated without the mesh and the sponge material installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 1. Spark plug cable 9. Install the panel.
U3P281E0.book Page 12 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Insert the tailpipe into the muffler, and then install and tighten the bolt. EAU41230 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. NOTE: Make sure to align the bolt hole when inserting the tailpipe. EWA10980 WARNING ● ● 6 Always let the exhaust system cool prior to touching exhaust components.
U3P281E0.book Page 13 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU39930 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.
U3P281E0.book Page 14 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21370 Adjusting the throttle cable free play 2. To increase the throttle cable free play, turn the adjusting nut in direction (a). To decrease the throttle cable free play, turn the adjusting nut in direction (b). 3. Tighten the locknut. 1. Throttle cable free play adjusting nut 2. Locknut 3. Throttle cable free play 6 The throttle cable free play should measure 3.0–5.0 mm (0.12–0.
U3P281E0.book Page 15 Friday, April 21, 2006 4:02 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU39820 Tires Tire inspection EWA10460 WARNING To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA14380 WARNING ● ● The tire air pressure must be checked and adjusted on cold tires (i.e.
U3P281E0.book Page 16 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 sively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. It is not recommended to patch a punctured tube.
U3P281E0.book Page 17 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22120 Adjusting the brake lever free play 1. Brake lever free play adjusting bolt 2. Locknut 3. Brake lever free play The brake lever free play should measure 10.0–20.0 mm (0.39–0.79 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting bolt in direction (a).
U3P281E0.book Page 18 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU41052 Checking the front and rear brake shoes Rear EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The wheels must be removed to check brake shoe lining thickness. ● To remove the front wheel: See page 6-27.
U3P281E0.book Page 19 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Drive chain slack 4. If the drive chain slack is incorrect, adjust it as follows. EAU40110 To adjust the drive chain slack 1. Loosen the brake pedal free play adjusting nut, axle nut, and locknut at each end of the swingarm. 1. Brake pedal free play adjusting nut 2. Locknut 3. Drive chain slack adjusting nut 2. To tighten the drive chain, turn the adjusting nut at each end of the swingarm in direction (a).
U3P281E0.book Page 20 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23013 Tightening torques: Locknut: 7.0 Nm (0.7 m·kgf, 5.1 ft·lbf) Axle nut: 60 Nm (6.0 m·kgf, 43 ft·lbf) 4. Adjust the brake pedal free play. (See page 6-17.) Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.
U3P281E0.book Page 21 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23111 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U3P281E0.book Page 22 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23152 6 EAU23200 EAUM1650 Checking and lubricating the brake lever Checking and lubricating the sidestand Lubricating the swingarm pivots The operation of the brake lever should be checked before each ride, and the lever pivots should be lubricated if necessary.
U3P281E0.book Page 23 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
U3P281E0.book Page 24 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU34221 Battery [TT-R90E(W)] The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery coupler 2. Battery 3. Battery band The battery is located behind cowling A.
U3P281E0.book Page 25 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● ways shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc.
U3P281E0.book Page 26 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23490 Replacing the fuse [TT-R90E(W)] 1. Fuse 2. Spare fuse 6 ECA10640 EAU24350 CAUTION: Supporting the motorcycle Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.
U3P281E0.book Page 27 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. EAU24360 Front wheel EAU41810 To remove the front wheel EWA10820 WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1.
U3P281E0.book Page 28 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU41691 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle from the right-hand side. NOTE: Make sure that the slot in the brake shoe plate fits over the retainer on the fork leg. EAU25080 Tightening torque: Axle nut: 35 Nm (3.5 m·kgf, 25 ft·lbf) 5. Adjust the brake lever free play. (See page 6-17.) 6.
U3P281E0.book Page 29 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod at the brake camshaft lever. EAU41651 1. 2. 3. 4. 1. 2. 3. 4. Brake rod Brake pedal free play adjusting nut Brake camshaft lever Wheel axle 3. Loosen the locknut and the drive chain slack adjusting nut on both ends of the swingarm. Axle nut Washer Drive chain slack adjusting nut Locknut 4. Loosen the axle nut. 5.
U3P281E0.book Page 30 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light. 6 EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U3P281E0.book Page 31 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25971 Troubleshooting chart [TT-R90(W)] EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. Check the compression. There is no fuel. Supply fuel. The engine does not start. Check the compression. 2. Compression 6 There is compression. Check the ignition. There is no compression.
U3P281E0.book Page 32 Monday, April 17, 2006 11:26 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25901 Troubleshooting chart [TT-R90E(W)] EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU40461 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM MOTORCYCLE CARE AND STORAGE EAU40651 Storage [TT-R90(W)] Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 CAUTION: ● ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
U3P281E0.book Page 4 Monday, April 17, 2006 11:26 AM MOTORCYCLE CARE AND STORAGE EAU26150 Storage [TT-R90E(W)] Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 CAUTION: ● ● 7 Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
U3P281E0.book Page 5 Monday, April 17, 2006 11:26 AM MOTORCYCLE CARE AND STORAGE °C (90 °F)]. For more information on storing the battery, see page 6-24. NOTE: Make any necessary repairs before storing the motorcycle.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM SPECIFICATIONS Dimensions: 8 Overall length: TT-R90 1525 mm (60.0 in) (AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP )(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR) (NZL)(PRT)(SWE)(ZAF) TT-R90 1550 mm (61.0 in) (CAN) TT-R90E 1525 mm (60.0 in) (AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP )(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR) (NZL)(PRT)(SWE)(ZAF) TT-R90E 1550 mm (61.0 in) (CAN) Overall width: 605 mm (23.8 in) Overall height: 865 mm (34.1 in) Seat height: 625 mm (24.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM SPECIFICATIONS Fuel: Recommended fuel: TT-R90 Regular unleaded gasoline only (AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP )(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR) (PRT)(SWE)(ZAF) TT-R90 Unleaded gasoline only (AUS)(NZL) TT-R90E Regular unleaded gasoline only (AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP )(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR) (PRT)(SWE)(ZAF) TT-R90E Unleaded gasoline only (AUS)(NZL) Fuel tank capacity: 4.2 L (1.11 US gal) (0.92 Imp.gal) Fuel reserve amount: 0.
U3P281E0.book Page 3 Monday, April 17, 2006 11:26 AM SPECIFICATIONS Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper Wheel travel: 110.0 mm (4.33 in) Rear suspension: Type: Swingarm (monocross) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 95.0 mm (3.74 in) Electrical system: Ignition system: CDI Battery: Model: TT-R90E GT4B-5 Voltage, capacity: TT-R90E 12 V, 2.5 Ah Fuse: 8 Fuse: TT-R90E 10.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM CONSUMER INFORMATION EAU26351 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: EAU26390 Key identification number [TT-R90E(W)] TT-R90E(W) 1. Vehicle identification number 1.
U3P281E0.book Page 2 Monday, April 17, 2006 11:26 AM CONSUMER INFORMATION EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-7.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM INDEX A Accessories and replacement parts ..... 6-16 Air filter element, cleaning .................... 6-10 H B Battery [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 .....................
U3P281E0.book Page 1 Monday, April 17, 2006 11:26 AM YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.04-0.
