Yamaha 5HN-28199-13, LIT-11626-16-27 2

Contents

Page Page TT-R90R OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A 1st Edition, April Printed in Japan P/N. LIT-11626-16-27 INTRODUCTION Page IMPORTANT NOTICE SAFETY INFORMATION Page Page Page HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION CAUTION: FINDING THE REQUIRED PAGE MANUAL FORMAT HOW TO READ DESCRIPTIONS ILLUSTRATED SYMBOLS (Refer to the illustration) Page CONTENTS CHAPTER GENERAL INFORMATION FUEL STARTING AND OPERATION ENGINE DESCRIPTION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER MODEL LABEL IMPORTANT INFORMATION INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY Page IMPORTANT INFORMATION/ CHECKING OF CONNECTION SPECIAL TOOLS Part number Tool name/How to use Illustration Page Page CONTROL FUNCTIONS INFO CONTROL FUNCTIONS FRONT BRAKE LEVER REAR BRAKE PEDAL FUEL COCK STARTER LEVER (CHOKE) CONTROL FUNCTIONS/FUEL INFO FUEL STARTING AND OPERATION INFO STARTING AND OPERATION STARTING A COLD ENGINE STARTING A WARM ENGINE WARMING UP GENERAL SPECIFICATIONS SPEC GENERAL SPECIFICATIONS Page Page MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Page Page Page Page Page Page Page Page Page Page GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS SPEC GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS CABLE ROUTING DIAGRAM SPEC CABLE ROUTING DIAGRAM B - B C - C D - D F - F Page MAINTENANCE INTERVALS/ PERIODIC MAINTENANCE AND LUBRICATION PRE-OPERATIONINSPECTION AND MAINTENANCE SERVICE NOTES: GENERAL INSPECTION AND MAINTENANCE ENGINE/THROTTLE CABLE ADJUSTMENT/ AIR FILTER CLEANING 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 ENGINE OIL LEVEL INSPECTION ADJ ENGINE OIL REPLACEMENT ADJ Recommended 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 PILOT AIR SCREW ADJUSTMENT Oil 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 IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT ADJ Valve clearance (cold): Intake valve: 0.05~ 0.09 mm (0.0020 ~ 0.0035 in) Exhaust valve: SPARK ARRESTER CLEANING (For USA) ADJ CHASSIS/FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT ADJ Axle nut: 60 Nm (6.0 m • kg, 43 ft • lb) FRONT FORK INSPECTION REAR SHOCK ABSORBER INSPECTION REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT TIRE PRESSURE CHECK ADJ Standard installation position: Groove b TIRE PRESSURE CHECK Standard tire pressure: SPOKES INSPECTION AND TIGHTENING WHEEL INSPECTION STEERING HEAD INSPECTION AND ADJUSTMENT STEERING HEAD INSPECTION AND ADJUSTMENT ADJ Steering ring nut adjustment steps: Ring nut wrench: YU-1268/90890-01268 YM-33975/90890-01403 STEERING HEAD INSPECTION AND ADJUSTMENT ON: LUBRICATION ADJ LUBRICATION ELECTRICAL/SPARK PLUG INSPECTION ADJ ELECTRICAL SPARK PLUG INSPECTION Spark plug gap: 0.6 ~ 0.7 mm (0.02 ~ 0.03 in) CARBURETOR ENG CARBURETOR CARBURETOR DISASSEMBLY Page INSPECTION Carburetor Needle valve Throttle valve Jet needle Standard clip position: No.2 Groove Float height Float height: Page Page CYLINDER HEAD ENG CYLINDER HEAD Page REMOVAL POINTS Cylinder head ASSEMBLY AND INSTALLATION Installation steps: Page CAMSHAFT AND ROCKER ARMS ENG CAMSHAFT AND ROCKER ARMS Page Page VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS Page Valve spring Free 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: Lapping steps: Do not let the compound enter the gap between the valve stem and the guide Hitting the valve tip with excessive force could damage the valve CYLINDER AND PISTON ENG CYLINDER AND PISTON Piston Piston pin puller set: YU-1304/90890-01304 Piston ring Cylinder and piston Page Side clearance Limit Top ring 0.030 ~ 0.065 mm 0.12 mm Page Cylinder ●Be careful not to damage the timing chain damper during installation ●Pass the timing chain through the timing chain cavity CLUTCH ENG CLUTCH CRANKCASE COVER (LEFT AND RIGHT) Page Page Page Page ASSEMBLY AND INSTALLATION Primary clutch Clutch Clutch release adjustment Locknut: KICK AXLE ENG KICK AXLE SHIFT SHAFT ENG SHIFT SHAFT Page OIL PUMP ENG OIL PUMP Page Page CDI MAGNETO ENG CDI MAGNETO Rotor Cover the crankshaft end with the box wrench for protection Flywheel puller: YU-33270-B/90890-01362 CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT Page Crankshaft Runout 0.03 mm limit Side SHIFT FORK, SHIFT CAM AND TRANSMISSION ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION Page Shift fork, shift cam and transmission Transmission, shift cam shift fork FRONT WHEEL AND REAR WHEEL CHAS FRONT WHEEL AND REAR WHEEL FRONT WHEEL AND FRONT BRAKE Page REAR WHEEL AND REAR BRAKE Page Wheel bearing (if necessary) Wheel Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in) FRONT FORK CHAS FRONT FORK FRONT FORK DISASSEMBLY Page HANDLEBAR CHAS HANDLEBAR STEERING STEERING CHAS SWINGARM CHAS SWINGARM Page ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC – + ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS IGNITION SYSTEM ELEC – + IGNITION SYSTEM INSPECTION STEPS Dynamic spark tester: Pocket tester: SPARK GAP TEST Minimum 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 Page Page CARBURETOR HEATING SYSTEM ELEC – + CARBURETOR HEATING SYSTEM COUPLERS AND LEADS CONNECTION THERMO SWITCH INSPECTION Inspection steps: Tester (+) lead → Black 1 Tester (–)lead → Black Page NOISE REGULATION/MAINTENANCE RECORD ELEC – + NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: MAINTENANCE RECORD