Yamaha 5HN-28199-13 manuals
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Yamaha 5HN-28199-13 Manual
132 pages 10.03 Mb
3 TT-R90ROWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A 1st Edition, April Printed in Japan P/N. LIT-11626-16-27 4 INTRODUCTION6 IMPORTANT NOTICESAFETY INFORMATION 10 HOW TO USETHIS MANUAL PARTICULARLY IMPORTANT INFORMATION CAUTION: FINDING THE REQUIRED PAGE 11 MANUAL FORMATHOW TO READ DESCRIPTIONS 12 ILLUSTRATED SYMBOLS (Refer to the illustration)14 CONTENTSCHAPTER GENERAL INFORMATION FUEL STARTING AND OPERATION SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS CABLE ROUTING DIAGRAM REGULAR INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE AND PRE-OPERATIONINSPECTION AND MAINTENANCE CHASSIS ELECTRICAL 15 ENGINE16 DESCRIPTION17 MACHINE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER MODEL LABEL 18 IMPORTANT INFORMATION INFOIMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 20 IMPORTANT INFORMATION/ CHECKING OF CONNECTION21 SPECIAL TOOLSPart number Tool name/How to use Illustration 24 CONTROL FUNCTIONS INFOCONTROL FUNCTIONS 25 FRONT BRAKE LEVERREAR BRAKE PEDAL FUEL COCK STARTER LEVER (CHOKE) 26 CONTROL FUNCTIONS/FUEL INFOFUEL 27 STARTING AND OPERATION INFOSTARTING AND OPERATION STARTING A COLD ENGINE STARTING A WARM ENGINE WARMING UP Before starting off, be sure to turn up or remove the side stand ENGINE BREAK-IN After the break-inperiod, check every fitting and fastener for looseness If any loose is found, retighten it securely See “Engine break-inSection” prior to operating engine for the first time 28 GENERAL SPECIFICATIONS SPECGENERAL SPECIFICATIONS 31 MAINTENANCE SPECIFICATIONS SPECMAINTENANCE SPECIFICATIONS ENGINE 42 GENERAL TORQUE SPECIFICATIONSDEFINITION OF UNITS SPEC GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS 43 CABLE ROUTING DIAGRAM SPECCABLE ROUTING DIAGRAM 44 B - BC - C D - D F - F 46 MAINTENANCE INTERVALS/ PERIODIC MAINTENANCE AND LUBRICATION47 PRE-OPERATIONINSPECTION AND MAINTENANCESERVICE NOTES: GENERAL INSPECTION AND MAINTENANCE 48 ENGINE/THROTTLE CABLE ADJUSTMENT/ AIR FILTER CLEANING49 AIR FILTER CLEANING●Do not twist the element when squeezing the element ●Leaving too much of solvent in the ele- ment may result in poor starting 50 ENGINE OIL LEVEL INSPECTION ADJ51 ENGINE OIL REPLACEMENT ADJRecommended engine oil classi- fication: API STANDARD: API “SE/SF” or higher grade (Designed primarily for motor- cycles) ●Do not add any chemical additives or use oils with a grade of CD a or higher Do not use oils labeled “ENERGY CON- SERVING II” ●Do not allow foreign materials to enter the crankcase ENGINE OIL REPLACEMENT 52 PILOT AIR SCREW ADJUSTMENTOil quantity: Periodic oil change: 0.8 L (0.70 Imp qt, 0.85 US qt) PILOT AIR SCREW ADJUSTMENT Adjusting steps: Pilot air screw: 1-3/4turns out 53 IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT54 VALVE CLEARANCE ADJUSTMENT ADJValve clearance (cold): Intake valve: 0.05~ 0.09 mm (0.0020 ~ 0.0035 in) Exhaust valve: 0.08~ 0.12 mm (0.031 ~ 0.047 in) Checking steps: Turning in → Valve clearance is decreased. Turning out → Valve clearance is increased Valve adjusting tool: YM-8035/90890-01311 55 SPARK ARRESTER CLEANING (For USA) ADJ56 CHASSIS/FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT57 DRIVE CHAIN SLACK ADJUSTMENT ADJ58 Axle nut:60 Nm (6.0 m • kg, 43 ft • lb) FRONT FORK INSPECTION REAR SHOCK ABSORBER INSPECTION REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 59 TIRE PRESSURE CHECK ADJStandard installation position: Groove b TIRE PRESSURE CHECK Standard tire pressure: 100 kPa (1.00 kgf/cm2, 14.5 psi) 60 SPOKES INSPECTION AND TIGHTENINGWHEEL INSPECTION STEERING HEAD INSPECTION AND ADJUSTMENT 61 STEERING HEAD INSPECTION AND ADJUSTMENT ADJSteering ring nut adjustment steps: Ring nut wrench: YU-1268/90890-01268 YM-33975/90890-01403 Ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb) Avoid over-tightening Ring nut (final tightening): 1 Nm (0.1 m • kg, 0.7 ft • lb) 62 STEERING HEAD INSPECTION AND ADJUSTMENTON: 63 LUBRICATION ADJLUBRICATION 64 ELECTRICAL/SPARK PLUG INSPECTION ADJELECTRICAL SPARK PLUG INSPECTION Spark plug gap: 0.6 ~ 0.7 mm (0.02 ~ 0.03 in) Standard spark plug: CR6HSA (NGK) U20FSR-U(DENSO) 65 CARBURETOR ENGCARBURETOR 66 CARBURETOR DISASSEMBLY68 INSPECTIONCarburetor Needle valve Throttle valve 69 Jet needleStandard clip position: No.2 Groove Float height Float height: 15.5 ~ 16.5 mm (0.61 ~ 0.65 in) Measurement and adjustment steps: 72 CYLINDER HEAD ENGCYLINDER HEAD 74 REMOVAL POINTSCylinder head 75 ASSEMBLY AND INSTALLATIONInstallation steps: 77 CAMSHAFT AND ROCKER ARMS ENGCAMSHAFT AND ROCKER ARMS 80 VALVES AND VALVE SPRINGS ENGVALVES AND VALVE SPRINGS 82 Valve springFree length (valve spring): Intake: 28.32 mm (1.11 in) <Limit>: 26.9 mm (1.06 in) Spring tilt limit: Intake: 2.5˚/1.2 mm (0.05 in) Exhaust: 2.5˚/1.2 mm (0.05 in) Valve seat Valve seat width: Intake: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Measurement steps: 83 Lapping steps:Do not let the compound enter the gap between the valve stem and the guide 84 Hitting the valve tip with excessive force could damage the valve85 CYLINDER AND PISTON ENGCYLINDER AND PISTON 86 PistonPiston pin puller set: YU-1304/90890-01304 Piston ring Cylinder and piston Measurement steps: 1st step: 88 Side clearanceLimit Top ring 0.030 ~ 0.065 mm 0.12 mm 2nd ring 0.020 ~ 0.055 mm End gap ~ 0.25 mm 0.4 mm (0.004 ~ 0.010 in) ~ 0.7 mm (0.01 ~ 0.03 in) 90 Cylinder●Be careful not to damage the timing chain damper during installation ●Pass the timing chain through the timing chain cavity 91 CLUTCH ENGCLUTCH CRANKCASE COVER (LEFT AND RIGHT) 96 ASSEMBLY AND INSTALLATION Primary clutchClutch Clutch release adjustment Locknut: 97 KICK AXLE ENGKICK AXLE 98 SHIFT SHAFT ENGSHIFT SHAFT 100 OIL PUMP ENGOIL PUMP 103 CDI MAGNETO ENGCDI MAGNETO 104 RotorCover the crankshaft end with the box wrench for protection Flywheel puller: YU-33270-B/90890-01362 105 CRANKCASE AND CRANKSHAFT ENGCRANKCASE AND CRANKSHAFT 107 CrankshaftRunout 0.03 mm limit Side 0.10 ~ 0.40 mm clearance (0.0039 ~ 0.0157 in) Radial 0.010 ~ 0.025 mm 0.05 mm (0.0004 ~ 0.0010 in) Crack 42.95 ~ 43.00 mm width (1.691 ~ 1.693 in) Crankcase Quick gasket®: ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 108 SHIFT FORK, SHIFT CAM AND TRANSMISSION ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION 110 Shift fork, shift cam and transmissionTransmission, shift cam shift fork 111 FRONT WHEEL AND REAR WHEEL CHASFRONT WHEEL AND REAR WHEEL FRONT WHEEL AND FRONT BRAKE 113 REAR WHEEL AND REAR BRAKE115 Wheel bearing (if necessary)Wheel Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in) Brake lining Brake shoe lining thickness a: Standard: Front: 3.0 mm (0.12 in) Rear: 4.0 mm (0.16 in) Limit: 2.0 mm (0.08 in) 116 FRONT FORK CHASFRONT FORK 117 FRONT FORK DISASSEMBLY119 HANDLEBAR CHASHANDLEBAR 120 STEERINGSTEERING CHAS 121 SWINGARM CHASSWINGARM 123 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC – +ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 124 IGNITION SYSTEM ELEC – +IGNITION SYSTEM INSPECTION STEPS Dynamic spark tester: Pocket tester: YM-34487 YU-3112-C/90890-03112 Ignition checker: 125 SPARK GAP TESTMinimum spark gap: 6.0 mm (0.24 in) COUPLERS AND LEADS CONNECTION INSPECTION “ENGINE STOP” SWITCH INSPECTION Tester (+) lead → Black/White lead 1 Tester (–)lead → Black lead B/W tor position 128 CARBURETOR HEATING SYSTEM ELEC – +CARBURETOR HEATING SYSTEM 129 COUPLERS AND LEADS CONNECTIONTHERMO SWITCH INSPECTION Inspection steps: Tester (+) lead → Black 1 Tester (–)lead → Black 131 NOISE REGULATION/MAINTENANCE RECORD ELEC – +NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: MAINTENANCE RECORD
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