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Yamaha RS90NL Supplementary Service Manual
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Yamaha RS90NL Supplementary Service Manual

Yamaha RS90NL Supplementary Service Manual

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SUPPLEMENTARY SERVICE MANUAL
LIT-12618-02-47
RS90NL
RS90NRL
RS90RSL
RS90GTL
RS90MSL
8GE-28197-10

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  • Page 1 SUPPLEMENTARY SERVICE MANUAL RS90NL RS90NRL RS90RSL RS90GTL RS90MSL LIT-12618-02-47 8GE-28197-10...
  • Page 2 This Supplementary Service Manual has been prepared to introduce new service and new data for the RS90NL, RS90NRL, RS90RSL, RS90GTL, RS90MSL. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following man-...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment POWR 3 Chassis CHAS 4 Power train 5 Engine 6 Cooling system 7 Carburetion...
  • Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL CARBURETION CARB – ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 6: Table Of Contents

    GENERAL INFORMATION SECONDARY SHAFT ........56 INSTALLATION..........56 SECONDARY SHAFT AND DRIVE CHAIN SPECIAL TOOLS ..........1 HOUSING INSTALLATION......58 FOR POWER TRAIN ........1 BRAKE .............. 60 BRAKE CALIPER DISASSEMBLY ....63 PERIODIC INSPECTION AND BRAKE CALIPER INSTALLATION ....63 ADJUSTMENT RS90N/RS90NR/RS90RS/RS90MS ....

  • Page 7: General Information

    SPECIAL TOOLS INFO GENERAL INFORMATION SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: •...

  • Page 8: Periodic Inspection And Adjustment

    INTRODUCTION/PERIODIC MAINTENANCE CHART FOR INSP THE EMISSION CONTROL SYSTEM PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer ser- vice life.

  • Page 9: General Maintenance And Lubrication Chart

    INSP GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART Every Initial Pre-opera- 1 month or Seasonally Item Remarks tion check 800 km or 4,000 km (Daily) (500 mi) (2,500 mi) (40 hr) (200 hr) Check oil level. Engine oil * Replace.
  • Page 10 INSP GENERAL MAINTENANCE AND LUBRICATION CHART Every Initial Pre-opera- 1 month or Seasonally Item Remarks tion check 800 km or 4,000 km (Daily) (500 mi) (2,500 mi) (40 hr) (200 hr) Steering column bearing Lubricate with specified grease. Ski and front suspension Lubricate with specified grease.

  • Page 11: Chassis

    BRAKE LEVER ADJUSTMENT (RS90N/RS90NR/RS90RS/ INSP RS90GT)/LUBRICATION CHASSIS BRAKE LEVER ADJUSTMENT (RS90N/RS90NR/RS90RS/RS90GT) 1. Adjust: • brake lever position a Adjustment steps: • While pushing the brake lever forward, loosen the locknut 1. • While pushing the brake lever forward, turn the adjusting bolt 2 in direction b or c until the brake lever is in the desired position.
  • Page 12 INSP LUBRICATION Front and rear suspension È 1. Use a grease gun to inject grease into the nip- ples 1 and 2 (Both side). 2. Apply grease 3. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A È Front É...
  • Page 13 INSP LUBRICATION Ë Ë Rear (RS90MS) 1 Nipple...

  • Page 14: Tuning

    INSP CARBURETOR TUNING TUNING CARBURETOR TUNING The carburetors are set at the factory to run at tem- peratures of 0 °C ~ –20 °C (32 °F ~ –4 °F) at sea level. If the machine is to be operated under condi- tions other than those specified above, the carbure- tors must be properly adjusted.
  • Page 15 Use the chart in CHAPTER 9 to select main jets according to variations in elevation and tempera- ture. NOTE: These jetting specifications are subject to change. Consult the latest technical information from Yamaha to be sure you have the most up-to-date jetting specifications. 1 Main jet 2 Pilot jet...
  • Page 16 INSP CARBURETOR TUNING Guide for carburetion...
  • Page 17 INSP CARBURETOR TUNING A Standard main jet B Main jet whose diameter is 10% smaller than stan- dard C Main jet whose diameter is 10% larger than standard CAUTION: If the air filter case is removed from the carbu- retors, the change in pressure in the intake will create a lean mixture that may cause severe engine damage.
  • Page 18 INSP CARBURETOR TUNING Main jet selection chart Spark plug color Diagnosis Remedy Light tan or gray Carburetors are tuned prop- erly. Dry black or fluffy Mixture is too rich. Replace the main jet with the next smaller size. deposits White or light gray Mixture is too lean.
  • Page 19 INSP CARBURETOR TUNING Trouble Diagnosis Adjustment Poor performance at Clogged air vent Remove the air vent hose and clean it. normal speeds: Clogged or loose main jet • Remove the main jet, clean it with compressed • Excessive fuel con- air, and then install it.

  • Page 20: Clutch

    INSP CLUTCH CLUTCH G Green P Pink High altitude S Silver Specifications Model: RS90N ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft)
  • Page 21 INSP CLUTCH G Green P Pink S Silver Specifications Model: RS90NR/RS90RS ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...
  • Page 22 INSP CLUTCH G Green O Orange P Pink S Silver Y Yellow Specifications Model: RS90GT ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft)
  • Page 23 INSP CLUTCH O Orange P Pink S Silver Specifications Model: RS90MS ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...
  • Page 24 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop.

  • Page 25: Gear Selection

    INSP GEAR SELECTION 1 Chain and sprocket part number È Parts name É Teeth & links Ê Parts no. Ë Standard 18 teeth 8FA-17682-80 RS90MS 19 teeth 8FA-17682-90 20 teeth 8FA-17682-00 Ì Drive sprocket 21 teeth 8FA-17682-10 RS90N/RS90NR/RS90RS 22 teeth 8FA-17682-20 RS90GT 23 teeth...
  • Page 26 INSP GEAR SELECTION 4 Secondary spring twist angle È Seat É Sheave 10° 40° 70° 100° 20° 50° 80° 110° 30° 60° 90° 120° 5 Torque cam (secondary spring seat) É Effects Ê Part no. Ë Cam angle Ì Identification mark Í...
  • Page 27 INSP GEAR SELECTION 6 Primary spring Ì Spring rate Ð Outside Í Preload Ï Wire gauge Ò Free length Ë Parts No. Î Color Ñ No. of coils Ó Standard N/mm diameter N (kg) mm (in) mm (in) (kg/mm) mm (in) 90501-551L3 19.6 (2.00) 294 (30)
  • Page 28 INSP GEAR SELECTION 7 Clutch weight É Weight g (oz) È Parts No. Ê Shape & ID mark Ë Standard without bush and rivets 8BU-17605-20 45.41 (1.603) RS90MS 8CH-17605-10 35.32 (1.247) 8DG-17605-00 34.26 (1.209) 8DJ-17605-00 37.77 (1.333) 8DN-17605-10 39.76 (1.404) RS90N/RS90NR/ 8ES-17605-00 54.63 (1.928)
  • Page 29 INSP GEAR SELECTION 8 Weight rivets Ê Length Ë Weight È Parts No. É Material Ì Standard Í Effects mm (in) g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) Î Increased force 3.6 (0.127) 90261-06006 Steel 17.2 (0.677) with hole IN, OUT: RS90N/RS90NR/ 90261-06034 Steel...

  • Page 30: Front Suspension

    INSP FRONT SUSPENSION FRONT SUSPENSION È Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut 1. • Turn the spring seat 2 in or out. RS90N/RS90NR/RS90RS Standard Spring seat Shorter ← → Longer distance É Harder ← →...
  • Page 31 INSP FRONT SUSPENSION CAUTION: Be sure that the left and right spring preloads are the same. WARNING These shock absorber contain highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assemblies. Do not subject the shock absorber assemblies to flames or high heat, which could cause it to explode.
  • Page 32 INSP FRONT SUSPENSION/REAR SUSPENSION Compression damping force adjustment (RS90GT) The compression damping force can be adjusted by turning the adjuster 1. 12 clicks out 7 clicks out 2 clicks out Adjuster position Minimum Standard Maximum Turns out b* ← → Turns in a Compres- Soft ←...

  • Page 33: Rear Suspension

    INSP REAR SUSPENSION Adjustment steps: È • Remove the stopper band bolts 1, nuts and washers. • Adjust the length of the stopper band(s) 2 by No.1 inserting the bolts in different holes. No.2 No.3 Standard setting: No.4 No. 1 hole (RS90N/RS90NR/RS90RS/ No.5 RS90MS) No.6...
  • Page 34 INSP REAR SUSPENSION Spring preload È 1. Adjust: • Spring preload Adjustment step: Front side • Loosen the locknut 1. • Turn the spring seat 2 in or out. RS90N/RS90NR/RS90RS Standard Spring seat Shorter ← → Longer distance Harder ← →...

  • Page 35: Rs90N/Rs90Nr/Rs90Rs/Rs90Ms

    INSP REAR SUSPENSION Rear side È • Turn the adjuster 1 to proper position. RS90N/RS90NR/RS90RS/RS90MS Spring adjuster position Spring rate Soft Medium Hard Standard WARNING Always adjust both spring preloads (left and É right) to the same setting. Uneven adjustment can cause poor handling and loss of stability.
  • Page 36 INSP REAR SUSPENSION CAUTION: Be sure to stop the remote adjustment dial at a marked position around the dial where there is a click. WARNING This shock absorber contains highly pressur- ized nitrogen gas. It could explode by improper handling, causing injury, or property damage. •...
  • Page 37 INSP REAR SUSPENSION Control rod (RS90N/RS90NR/RS90RS/RS90MS) 1. Adjust: • Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 in or out to adjust the control rod stroke.
  • Page 38 INSP REAR SUSPENSION • Check the adjuster length d using the scale on the special wrench 3 included in the owner’s tool kit as shown. Make sure that the rim e of the control rod body is within the range f of the scale.
  • Page 39 CHAS STEERING CHASSIS STEERING RS90N/RS90NR/RS90RS/RS90MS É È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 11 ft 15 Nm (1.5 m • • Ê: 16 Nm (1.6 m kg, 11 ft • • Ë: 21 Nm (2.1 m kg, 15 ft •...
  • Page 40 CHAS STEERING É È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 11 ft 15 Nm (1.5 m • • Ê: kg, 11 ft 16 Nm (1.6 m • • Ë: kg, 15 ft 21 Nm (2.1 m •...
  • Page 41 CHAS STEERING RS90GT Q’ty Remarks Order Job name/Part name Handlebar removal Remove the parts in the order listed below. Handlebar cover Plastic band Thumb warmer lead coupler Disconnect. Thumb warmer adjustment switch lead Disconnect. coupler Engine stop switch coupler Disconnect. Throttle switch coupler Disconnect.
  • Page 42 CHAS STEERING Order Job name/Part name Q’ty Remarks Master cylinder assembly NOTE: Handlebar holder (upper) After installing all parts, refer to “CABLE Cable holder ROUTING” in CHAPTER 9, to check the Handlebar cable and lead routings. Handlebar holder (lower) For installation, reverse the removal proce- dure.

  • Page 43: Installation

    CHAS STEERING INSTALLATION 1. Install: • Relay arms 1 • Bushings • Washers 2 • Clips 3 Relay arm bolt: 67 Nm (6.7 m · kg, 48 ft · lb) 2. Install: • Idler arm 1 • Bushings • Washers •...
  • Page 44 CHAS STEERING 3. Install: • Tie rod 1 • Locknuts 2 • Joints 3 È Tie rod part É Set length Ê Tie rod length b number 8ES-23830-00 (RS90N/ 424.0 mm 361.0 mm RS90NR/ (16.69 in) (14.21 in) RS90RS/ RS90GT) È...
  • Page 45 CHAS STEERING 7. Install: • Steering shaft 1 • Locknuts 2 • Joints 3 È Steering Shaft É Set length Ê Shaft length b part number 8FA-23840-00 227.8 mm 169.8 mm (8.97 in) (6.69 in) NOTE: Install the silver-colored end c of the joint 3 to the steering column 1.
  • Page 46 CHAS STEERING 9. Install: (RS90N/RS90NR/RS90RS/RS90MS) • Handlebar 1 • Handlebar holders 2 CAUTION: First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. NOTE: • The handlebar holders should be installed with the punch marks a facing forward.

  • Page 47: Ski

    CHAS RS90N/RS90NR/RS90RS/RS90GT Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below. Cotter pin Bolt Collar Ski stopper For installation, reverse the removal proce- dure.

  • Page 48: Rs90Ms

    CHAS RS90MS Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below. Cotter pin Bolt Collar Collar Ski stopper For installation, reverse the removal proce- dure.

  • Page 49: Front Suspension

    CHAS FRONT SUSPENSION FRONT SUSPENSION Q’ty Remarks Order Job name/Part name Front suspension removal Remove the parts in the order listed below. Refer to “SKI”. Front cover Shock absorber Collar Cotter pin Tie rod Disconnect. Steering arm Ski column Bushing Upper arm Lower arm Bushing...
  • Page 50 CHAS FRONT SUSPENSION Q’ty Remarks Order Job name/Part name Stabilizer Bushing Steering knuckle Collar For installation, reverse the removal proce- dure.

  • Page 51: Power Train

    POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT Q’ty Remarks Order Job name/Part name Primary sheave disassembly Remove the parts in the order listed below. Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave...

  • Page 52: Drive Chain Housing

    POWR DRIVE CHAIN HOUSING DRIVE CHAIN HOUSING WITHOUT REVERSE MODEL Order Job name/Part name Q’ty Remarks Drive chain housing removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Right side cover/brake caliper/parking Refer to “BRAKE”. brake Shim —...
  • Page 53 POWR DRIVE CHAIN HOUSING Q’ty Remarks Order Job name/Part name Spacer Drive sprocket Spacer Driven sprocket Spacer Drive chain Drive chain housing For installation, reverse the removal proce- dure.

  • Page 54: Installation

    POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the follow- ing. È Make sure that the bearing seals face towards the drive chain as shown. É Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. É...

  • Page 55: With Reverse Model

    POWR DRIVE CHAIN HOUSING WITH REVERSE MODEL Order Job name/Part name Q’ty Remarks Drive chain housing removal Remove the parts in the order listed below. Secondary sheave Refer to “SECONDARY SHEAVE”. Right side cover/brake caliper/parking Refer to “BRAKE”. brake Shim —...
  • Page 56 POWR DRIVE CHAIN HOUSING Q’ty Remarks Order Job name/Part name Drive chain housing cover Rubber seal Washer Counter gear Spring Chain tensioner Washer t = 0.5 Spacer Spacer Spring Reverse driven gear Journal Washer Forward driven sprocket Spacer Reverse drive gear Washer Drive chain...
  • Page 57 POWR DRIVE CHAIN HOUSING Q’ty Remarks Order Job name/Part name Drive sprocket Spacer Plate Shaft Drive chain housing For installation, reverse the removal proce- dure.

  • Page 58: Removal

    POWR DRIVE CHAIN HOUSING REMOVAL 1. Remove: • Reverse driven gear 1 (driven sprocket for without reverse model) NOTE: While holding the front axle assembly with spanner wrench 2, loosen the reverse driven gear bolt. 2. Remove: • Drive sprocket nut 1 NOTE: While holding the secondary shaft with the second- ary shaft slide &...

  • Page 59: Installation

    POWR DRIVE CHAIN HOUSING INSTALLATION 1. During installation, pay attention to the follow- ing. È Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. É Make sure that the bearing seals face towards the È...
  • Page 60 POWR DRIVE CHAIN HOUSING 4. Install: • Shift rod 1 5. Adjust: • Shift rod length a Adjustment steps: • Move the shift lever to the “FWD.” position. • Loosen the locknuts 2. • Turn the shift rod 1 so that shift rod free play is 0 mm (in direction where a can be shortened appropriately) and then turn back the shift rod 1/2 turns.

  • Page 61: Secondary Shaft

    POWR SECONDARY SHAFT SECONDARY SHAFT INSTALLATION 1. Install: • Bearing collar nut 1 • Secondary shaft 2 NOTE: Install the bearing collar nut 1 with its chamfered side towards the secondary sheave. È Engine side É Secondary sheave side 2. Install: •...
  • Page 62 POWR SECONDARY SHAFT 5. Install: • Secondary shaft slide & holder 1 NOTE: • This procedure does not require the use of the collar 2 included with the special tool. • Install the end a of the secondary shaft slide & holder 1 to the engine.

  • Page 63: Secondary Shaft And Drive Chain Housing Installation

    POWR SECONDARY SHAFT SECONDARY SHAFT AND DRIVE CHAIN HOUSING INSTALLATION 1. Install: • Secondary shaft • Drive chain housing È Installation steps: • Install the secondary shaft. • Install the drive chain housing 1. • Tighten the bolts. Drive chain housing bolt: 43 Nm (4.3 m ·...
  • Page 64 POWR SECONDARY SHAFT 2. Measure: • Brake disc clearance a Out of the specification → Adjust. Brake disc clearance: 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) 3. Adjust: • Brake disc clearance Adjustment steps: • Remove the circlip 8. •...

  • Page 65: Brake

    POWR BRAKE BRAKE È: 6 Nm (0.6 m kg, 4.3 ft • • É: 18 Nm (1.8 m kg, 13 ft • • Ê: kg, 35 ft 48 Nm (4.8 m • • È Ê È É Q’ty Remarks Order Job name/Part name Brake pad removal Remove the parts in the order listed below.
  • Page 66 POWR BRAKE Q’ty Remarks Order Job name/Part name Brake caliper and parking brake Remove the parts in the order listed below. removal Brake fluid Drain. Brake hose Brake caliper assembly Parking brake cable Spring Parking brake assembly Collar Collar For installation, reverse the removal proce- dure.
  • Page 67 POWR BRAKE È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 13 ft 18 Nm (1.8 m • • È È É Q’ty Remarks Order Job name/Part name Brake caliper disassembly Remove the parts in the order listed below. Cap bolt Retaining pin Pad spring...

  • Page 68: Brake Caliper Disassembly

    POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons • Piston seals 1 Removal steps: • Using a wood of piece 2, lock the right piston. •...

  • Page 69: Rs90N/Rs90Nr/Rs90Rs/Rs90Ms

    POWR BRAKE RS90N/RS90NR/RS90RS/RS90MS Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain. Left handlebar switch Refer to “STEERING” in CHAPTER 3. Brake switch Brake lever Union bolt Holder Parking brake cable Disconnect.

  • Page 70: Rs90Gt

    POWR BRAKE RS90GT Order Job name/Part name Q’ty Remarks Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain. Left handlebar switch Refer to “STEERING” in CHAPTER 3. Brake switch Brake lever Union bolt Holder Parking brake cable Disconnect.

  • Page 71: Slide Rail Suspension

    POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION RS90N/RS90NR/RS90RS Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Slide rail suspension For installation, reverse the removal proce- dure.
  • Page 72 POWR SLIDE RAIL SUSPENSION È: 4 Nm (0.4 m kg, 2.9 ft • • É: 49 Nm (4.9 m kg, 35 ft • • Ê: kg, 43 ft 60 Nm (6.0 m • • Ë: kg, 80 ft 110 Nm (11.0 m •...
  • Page 73 POWR SLIDE RAIL SUSPENSION È È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 43 ft 60 Nm (6.0 m • • Ê: kg, 52 ft 72 Nm (7.2 m • • É Ê É È É É...
  • Page 74 POWR SLIDE RAIL SUSPENSION Ê É Ë Ì Ê Ì È È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 35 ft 49 Nm (4.9 m • •...
  • Page 75 POWR SLIDE RAIL SUSPENSION Ê É Ë Ì Ê Ì È È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 35 ft 49 Nm (4.9 m • •...
  • Page 76 POWR SLIDE RAIL SUSPENSION È: kg, 54 ft 75 Nm (7.5 m • • È Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly pro- cedure.

  • Page 77: Rs90Gt

    POWR SLIDE RAIL SUSPENSION RS90GT Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen. Slide rail suspension Collar For installation, reverse the removal proce- dure.
  • Page 78 POWR SLIDE RAIL SUSPENSION Order Job name/Part name Q’ty Remarks Slide rail suspension disassembly Remove the parts in the order listed below. Shock absorber adjuster assembly Stopper band Spacer Collar Collar Front pivot arm Shaft Suspension wheel Suspension wheel bracket Front pivot arm bracket Bushing Collar...
  • Page 79 POWR SLIDE RAIL SUSPENSION Q’ty Remarks Order Job name/Part name Rear shock absorber Collar Bushing Bearing Control rod assembly Spacer Collar Oil seal Bearing Rear pivot arm Rear pivot arm bracket Guide wheel Washer Bushing Shaft Shaft Shaft Suspension wheel Suspension wheel bracket...
  • Page 80 POWR SLIDE RAIL SUSPENSION Q’ty Remarks Order Job name/Part name Rear axle shaft Guide wheel Guide wheel Collar Tension adjuster Collar Collar Sliding frame For assembly, reverse the disassembly pro- cedure.

  • Page 81: Rs90Ms

    POWR SLIDE RAIL SUSPENSION RS90MS È: 72 Nm (7.2 m kg, 52 ft • • È È Order Job name/Part name Q’ty Remarks Slide rail suspension removal Remove the parts in the order listed below. Rear axle nut Loosen. Tension adjuster Loosen.
  • Page 82 POWR SLIDE RAIL SUSPENSION È: 4 Nm (0.4 m kg, 2.9 ft • • É: 49 Nm (4.9 m kg, 35 ft • • Ê: kg, 43 ft 60 Nm (6.0 m • • Ë: 72 Nm (7.2 m kg, 54 ft •...
  • Page 83 POWR SLIDE RAIL SUSPENSION È È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 43 ft 60 Nm (6.0 m • • Ê: kg, 52 ft 72 Nm (7.2 m • • É Ê É È É É...
  • Page 84 POWR SLIDE RAIL SUSPENSION È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
  • Page 85 POWR SLIDE RAIL SUSPENSION È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 18 ft 25 Nm (2.5 m • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
  • Page 86 POWR SLIDE RAIL SUSPENSION È: kg, 43 ft 60 Nm (6.0 m • • É: 75 Nm (7.5 m kg, 54 ft • • È É È Q’ty Remarks Order Job name/Part name Shaft Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar...

  • Page 87: Assembly

    POWR SLIDE RAIL SUSPENSION ASSEMBLY 1. Apply: • ESSO beacon 325 grease or Aeroshell grease #7A (RS90N/RS90NR/RS90RS/ RS90MS) NOTE: Apply grease to the bushings 1 and the shaft 2 in the area a shown in the illustration. b 5 ~ 15 mm (0.20 ~ 0.59 in) 2.

  • Page 88: Installation

    POWR SLIDE RAIL SUSPENSION 5. Install: • Rear shock absorber adjuster assembly 1 • Guide 2 (RS90GT) NOTE: Install the guide after installing the rear shock absorber adjuster assembly. INSTALLATION 1. Adjust: • Track tension Refer to “TRACK TENSION ADJUSTMENT” in CHAPTER 2.
  • Page 89 POWR SLIDE RAIL SUSPENSION Control rod part numbers (RS90N/RS90NR/RS90RS/ RS90MS) È Control rod 1 É Length a mm (in) Ê Length b mm (in) Ë Length c mm (in) RS90N/RS90NR/ 2.5P × 2 = 5 228.8 (9.01) 198.7 (7.82) RS90RS (0.098P ×...
  • Page 90 POWR SLIDE RAIL SUSPENSION Control rod parts number (RS90GT) È Control rod 1 É Length a mm (in) Ê Length b mm (in) Ë Length c mm (in) RS90GT 277.3 (10.92) 150.5 (5.93) — Î Washer plate parts number Ì Control rod 1 Í...

  • Page 91: Front Axle And Track

    POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK Q’ty Remarks Order Job name/Part name Front axle and track removal Remove the parts in the order listed below. Drive chain housing Refer to “DRIVE CHAIN HOUSING”. Slide rail suspension Refer to “SLIDE RAIL SUSPENSION”. Secondary sheave Refer to “SECONDARY SHEAVE”.

  • Page 92: Installation

    POWR FRONT AXLE AND TRACK INSTALLATION È 1. Install: • Sprocket wheels • Guide wheels NOTE: • When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. • Position each sprocket wheel on the axle as shown in the illustration.

  • Page 93: Engine

    SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK RS90N/RS90NR/RS90RS/RS90GT Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below. Handlebar Refer to “STEERING” in CHAPTER 3. Rear cover Muffler protector Tail/brake light cover Tail/brake light sub-wire harness Disconnect.

  • Page 94: Rs90Ms

    SEAT AND FUEL TANK RS90MS È: 7 Nm (0.7 m kg, 5.1 ft • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 13 ft 18 Nm (1.8 m • • Ê È È È 6 É...

  • Page 95: Exhaust Pipe And Muffler

    EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER RS90MS È: È 11 Nm (1.1 m kg, 8.0 ft • • É: kg, 11 ft 16 Nm (1.6 m • • È Ê: kg, 14 ft 20 Nm (2.0 m • •...

  • Page 96: Carburetion

    CARB CARBURETORS AND FUEL PUMP CARBURETION CARBURETORS AND FUEL PUMP Q’ty Remarks Order Job name/Part name Carburetor disassembly Remove the parts in the order listed below. NOTE: The following procedure applies to all of the carburetors. Throttle stop screw Throttle cable holder Starter plunger Vacuum chamber cover Piston valve spring...
  • Page 97 CARB CARBURETORS AND FUEL PUMP Q’ty Remarks Order Job name/Part name Float chamber Float pin Float Needle valve Main jet Needle jet holder Needle jet Pilot jet For assembly, reverse the disassembly pro- cedure.

  • Page 98: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Model code number: 8GF1 (RS90N “USA/Canada”) 8GH1 (RS90NR “USA/Canada”) 8GH2 (RS90RS “Europe”) 8GG1 (RS90GT “USA/Canada”) 8GE1 (RS90MS “USA/Canada”) 8GE2 (RS90MS “Europe”) Dimensions: Overall length 2,755 mm (108.5 in) (RS90N/RS90NR/RS90RS/RS90GT) 3,300 mm (131.1 in) (RS90MS) Overall width 1,225 mm (48.2 in) (RS90N/RS90NR/RS90RS/RS90GT) 1,165 mm (45.9 in) (RS90MS)
  • Page 99 SPEC GENERAL SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Drive chain housing oil: Type Gear oil “GL-3” 75W or 80W Capacity 0.25 L (0.22 Imp qt, 0.26 US qt) Coolant: Filler cap opening pressure 95.0 ~ 125.0 kPa (0.95 ~ 1.25 kg/cm , 13.5 ~ 17.8 psi) Capacity 4.8 L (4.22 Imp qt, 5.07 US qt) (RS90N/RS90NR/RS90RS/ RS90GT)
  • Page 100 SPEC GENERAL SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Electrical: Ignition system Transistorized coil ignition Generator system A.C. magneto Headlight bulb type: Halogen bulb Bulb wattage × Quantity: 12 V, 60 W/55 W × 2 Headlight 12 V, 5 W/21 W × 2 (RS90N/RS90NR/RS90RS/RS90GT) Tail/Brake light LED (RS90MS) 14 V, 50 mA ×...

  • Page 101: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Cylinder head: Volume (with spark plug) 22.82 ~ 23.62 cm (1.39 ~ 1.44 cu.in) <Warpage limit> 0.10 mm (0.0039 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 79.000 ~ 79.010 mm (3.1102 ~ 3.1106 in) <Taper limit>...
  • Page 102 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Valves, valve seats, valve guides: Valve clearance (cold) Intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) Exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Valve dimensions Valve head diameter A Intake 29.9 ~ 30.1 mm (1.1772 ~ 1.1850 in) Exhaust 25.9 ~ 26.1 mm (1.0197 ~ 1.0276 in) Valve face width B...
  • Page 103 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Valve spring: Free length Intake 39.73 mm (1.56 in) <Limit> 37.74 mm (1.49 in) Exhaust 39.73 mm (1.56 in) <Limit> 37.74 mm (1.49 in) Installed length (valve closed) Intake 33.0 mm (1.30 in) Exhaust 33.0 mm (1.30 in) Compressed spring force (installed) Intake 136 ~ 158 N (13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)
  • Page 104 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Piston ring: Sectional sketch Top ring Ring type Barrel Dimensions (B × T) 1.00 × 2.80 mm (0.039 × 0.110 in) 2nd ring Top ring (same or no) Ring type Taper Dimensions (B × T) 1.00 ×...
  • Page 105 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Carburetor: Type × quantity CVK40 × 3 Manufacturer KEIHIN I.D. mark 8ES1 01 Main jet (M.J) #148 Main air jet (M.A.J) Jet needle (J.N) N425-BSJ00 Needle jet (N.J) W9554-26538#6 Pilot jet (P.J) Pilot air jet (P.A.J) #120 Pilot outlet...

  • Page 106: Power Train

    SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Transmission: Type V-belt automatic Range of ratio 3.8 ~ 1.0 : 1 Engagement speed r/min 3,400 ~ 3,800 r/min (RS90N/RS90NR/RS90RS) 3,300 ~ 3,700 r/min (RS90GT) 3,600 ~ 4,000 r/min (RS90MS) Shift r/min 8,250 ~ 8,750 r/min Sheave distance 267 ~ 270 mm (10.51 ~ 10.63 in) Sheave offset...
  • Page 107 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Rivet: Outer Part number 90261-06034 (RS90N/RS90NR/RS90RS/RS90GT) 90261-06028 (RS90MS) Material Steel (RS90N/RS90NR/RS90RS/RS90GT) Aluminum (RS90MS) Size 13.9 mm (0.547 in) (RS90N/RS90NR/RS90RS/RS90GT) 10.3 mm (0.406 in) (RS90MS) Quantity Hole quantity Inner None (RS90MS) Part number 90261-06034 Material Steel Size 13.9 mm (0.547 in) Quantity...
  • Page 108 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Track: Part number 8FA-47110-00 (RS90N/RS90NR/RS90RS/RS90GT) 8FS-47110-00 (RS90MS) Width 381.0 mm (15.0 in) (RS90N/RS90NR/RS90RS/RS90GT) 406.4 mm (16.0 in) (RS90MS) Length 3,072 mm (120.94 in) (RS90N/RS90NR/RS90RS/RS90GT) 4,115 mm (162.01 in) (RS90MS) Pitch 64.0 mm (2.52 in) (RS90N/RS90NR/RS90RS/RS90GT) 76.2 mm (3.00 in) (RS90MS) Number of links 48 (RS90N/RS90NR/RS90RS/RS90GT)
  • Page 109 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Shock absorber: Damping force Front Extension 590 N/0.3 m/s (60.2 kg/0.3 m/s, 132.6 lb/0.3 m/s) (RS90N/ RS90NR/RS90RS) 620 N/0.3 m/s (63.2 kg/0.3 m/s, 139.4 lb/0.3 m/s) (RS90MS) Compression 240 N/0.3 m/s (24.5 kg/0.3 m/s, 54.0 lb/0.3 m/s) (RS90N/ RS90NR) 190 N/0.3 m/s (19.4 kg/0.3 m/s, 42.7 lb/0.3 m/s) (RS90RS) 990 N/0.3 m/s (100.9 kg/0.3 m/s, 222.6 lb/0.3 m/s)

  • Page 110: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Frame: Frame material Monocoque (Aluminum) Seat height 765 mm (30.1 in) (RS90N/RS90NR/RS90RS/RS90MS) 720 mm (28.3 in) (RS90GT) Luggage box location Rear (RS90N/RS90NR/RS90RS/RS90MS) Front (RS90GT) Steering: Lock-to-lock angle (left) 29.0° (R ski) 34.5° (L ski) (RS90N/RS90NR/RS90RS/ RS90GT) 30.1°...
  • Page 111 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Shock absorber: Damping force Extension 730 N/0.3 m/s (74.4 kg/0.3 m/s, 164.1 lb/0.3 m/s) (RS90N/ RS90NR/RS90RS) 1,120 N/0.3 m/s (114.2 kg/0.3 m/s, 251.8 lb/0.3 m/s) (RS90GT) 930 N/0.3 m/s (94.8 kg/0.3 m/s, 209.1 lb/0.3 m/s) (RS90MS) Compression 480 N/0.3 m/s (48.9 kg/0.3 m/s, 107.9 lb/0.3 m/s) (RS90N/...

  • Page 112: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5° at 1,400 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T55873/MITSUBISHI Ignition spark gap 6.0 mm (0.24 in) 1.19 ~ 1.61 Ω at 20 °C (68 °F) Primary coil resistance Secondary coil resistance 8.5 ~ 11.5 kΩ...
  • Page 113 SPEC MAINTENANCE SPECIFICATIONS Model RS90N/RS90NR/RS90RS/RS90GT/RS90MS T.P.S. (throttle position sensor): Manufacturer KEIHIN Resistance 4 ~ 6 kΩ at 20 °C (68 °F) (Blue – Black) 0 ~ 4 kΩ at 20 °C (68 °F) (Yellow – Black) Oil level switch: Model/Manufacturer 8FA/ASTI Fuel sender: Model/Manufacturer...

  • Page 114: High Altitude Settings

    SPEC MAINTENANCE SPECIFICATIONS HIGH ALTITUDE SETTINGS Temperature –30 °C –10 °C 10 °C (–22 °F) (–14 °F) (50 °F) Altitude Idling speed (r/min) 0 ~ 200 m #150 #148 #148 1,400 (0 ~ 700 ft) 200 ~ 1,500 m #148 #148 #145 1,400...

  • Page 115: Engine

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Spark plug Cylinder head bolt (M10 × 1.25) See NOTE. Apply the engine oil. Cylinder head bolt Camshaft cap and cylinder head Apply the engine oil.
  • Page 116 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Crankcase (M9 × 1.25) Apply the engine oil. See NOTE. Crankcase (M8 × 1.25) Apply the engine oil. Crankcase (M6 × 1.0) Apply the engine oil. Primary sheave drive shaft assembly bolt Connecting rod and cap See NOTE.

  • Page 117: Power Train

    SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave See NOTE. Spider and sliding sheave 20.0 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) ®...
  • Page 118 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Brake lever adjusting bolt (RS90N/RS90NR/RS90RS/ RS90GT) Brake hose holder and coolant reservoir tank Slide rail suspension mounting bolt (M10) (RS90N/RS90NR/RS90RS/ RS90MS) Slide rail suspension mounting bolt (M10) (front (RS90GT) Apply grease* side) ®...
  • Page 119 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Control rod shaft and sliding frame (RS90N/RS90NR/RS90RS/ RS90MS) ® Rear pivot arm bracket and sliding frame (RS90GT) Apply LOCTITE Rear axle ® Set bolt (front axle) Apply LOCTITE Speed sensor Bearing holder...

  • Page 120: Chassis

    SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m · kg ft · lb Handlebar holder Steering joint bracket and steering column 2 (RS90N/RS90NR/RS90RS/ RS90MS) Steering joint and steering joint bracket (RS90N/RS90NR/RS90RS/ RS90MS) Grip end (RS90N/RS90NR/RS90RS/ RS90MS) Strap and handlebar (RS90MS) Steering column 1 (front)

  • Page 121: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasteners m · kg ft · lb with standard I.S.O. pitch threads. Torque specifi- 10 mm 6 mm cations for special components or assemblies are 12 mm 8 mm included in the applicable sections of this book.

  • Page 122: Cable Routing

    SPEC CABLE ROUTING 1 2 3 j k l...
  • Page 123 SPEC CABLE ROUTING CABLE ROUTING 1 Positive battery lead 2 Negative battery lead 3 Wire harness 4 Fasten the A.C. magneto lead and wire harness with the plastic band. 5 Negative battery lead coupler 6 Route the negative battery leads under the starter relay.
  • Page 124 SPEC CABLE ROUTING 1 2 3 j k l...
  • Page 125 SPEC CABLE ROUTING R Right handlebar switch lead cou- plers S Thumb warmer adjustment switch lead coupler T Grip warmer lead connectors U To the tail/brake light V Headlight beam switch coupler W Grip warmer adjustment switch lead coupler X Brake light switch lead coupler Y Route the starter cable over the left handlebar switch leads.
  • Page 126 SPEC CABLE ROUTING 1 2 3 j k l...
  • Page 127 SPEC CABLE ROUTING h To the headlights and meter assembly i Load control relay j Headlight relay k Carburetor heater relay l Back buzzer (with reverse mod- els) m Nut n Bolt o Install the starter motor lead ter- minal so that the terminal is bent upward.
  • Page 128 SPEC CABLE ROUTING...
  • Page 129 SPEC CABLE ROUTING 1 Headlight sub-wire harness 2 Fasten the headlight sub-wire harness at the positioning tape with the holder on the shroud. 3 Fasten the headlight sub-wire harness with the holder. 4 Fasten the headlight sub-wire harness with the clamp. 5 Fasten the headlight sub-wire harness at the positioning tape with the plastic band.
  • Page 130 SPEC CABLE ROUTING 2 3 4 5 6 7 8 9 0 A...
  • Page 131 SPEC CABLE ROUTING 1 Right handlebar switch 2 Fasten the right handlebar switch lead, thumb warmer lead, and grip warmer lead with the plastic band. Do not fasten the throttle cable. 3 Fasten the wire harness and main switch lead with the plastic band.
  • Page 132 SPEC CABLE ROUTING 2 3 4 5 6 7 8 9 0 A...
  • Page 133 SPEC CABLE ROUTING K Face the ends of the clamp upward. L Install the fuel tank breather hose onto the breather pipe until it contacts the running board sup- port. M To the speed sensor N 60 ~ 70 mm (2.4 ~ 2.8 in) O Route the float chamber air vent hoses behind the battery bracket.
  • Page 134 SPEC CABLE ROUTING...
  • Page 135 SPEC CABLE ROUTING 1 Headlight sub-wire harness 2 Install the ground lead terminal with the rectifier/regulator upper bolt. 3 Oil tank outlet hose 4 Fasten the starter motor lead and A.C. magneto lead with the holder. 5 Starter motor lead 6 Place the end of the coolant res- ervoir breather hose between the engine and the heat exchanger.
  • Page 136 SPEC CABLE ROUTING...
  • Page 137 SPEC CABLE ROUTING 1 Fuel pumps 2 Face the ends of each clamp outward. 3 Fuel hoses 4 Coolant reservoir 5 Fasten the fuel tank breather hose and speed sensor lead with the holder. Secure the frame cross member and the holder to the frame with the nut and bolt.
  • Page 138 SPEC CABLE ROUTING...
  • Page 139 SPEC CABLE ROUTING 1 To the starter motor 2 Starter motor lead 3 Negative battery lead 4 Positive battery lead 5 Ignitor unit 6 Ignitor unit bracket 7 Air filter case latch 8 Battery band 9 Battery cover 0 To the carburetor A Wire harness B Battery bracket C Frame cross member...
  • Page 140 SPEC CABLE ROUTING...
  • Page 141 SPEC CABLE ROUTING 1 Forward 2 Wire harness 3 Battery bracket 4 To the air filter case 5 A.C. magneto lead 6 Route the crankcase breather hose between the wire harness and the A.C. magneto lead, and then under the battery bracket. 7 Crankcase breather hose...
  • Page 142 SPEC CABLE ROUTING...
  • Page 143 SPEC CABLE ROUTING RS90N/RS90NR/RS90RS/ RS90MS 1 Throttle cable 2 Parking brake cable 3 Brake hose 4 Route the starter cable behind the throttle cable, right handlebar switch leads, left handlebar switch leads, brake hose, and parking brake cable. 5 Pass the brake hose, parking brake cable, and throttle cable through the guide.
  • Page 144 SPEC CABLE ROUTING...
  • Page 145 SPEC CABLE ROUTING 1 Pass the A.C. magneto lead and the wire harness through the cut- out in the front panel. 2 Front panel 3 To the parking brake 4 Wire harness 5 To the brake caliper 6 Route the starter cable under the throttle cable, brake hose, and parking brake cable.
  • Page 146 SPEC CABLE ROUTING...
  • Page 147 SPEC CABLE ROUTING RS90N/RS90NR/RS90RS 1 Position the tail/brake light switch lead coupler so that it is not pinched between the seat and tail/brake light bracket.
  • Page 148 SPEC CABLE ROUTING...
  • Page 149 SPEC CABLE ROUTING RS90GT 1 Position the tail/brake light switch lead coupler so that it is not pinched between the seat and tail/brake light bracket.
  • Page 150 SPEC CABLE ROUTING...
  • Page 151 SPEC CABLE ROUTING RS90MS 1 Sub-tail/brake light lead coupler 2 Fasten the sub-tail/brake light lead with the holder. 3 Sub-tail/brake light lead 4 Pass the tail/brake light sub-wire harness through the cutout in the tail/brake light cover. 5 Tail/brake light coupler 6 Muffler protector 7 Frame...
  • Page 152 WIRING DIAGRAM RS90N/RS90NR/RS90RS/RS90MS 2006 8FG-0F001-00/8GE-0F001-00 È É (BLACK) G/B Ch G L/Y L/R G L/R G G L/R G L/R R/B B B Dg (BLACK) (BLACK) Lg/W B/W Y/W Br/W Lg Br/Y Y/R G Lg/B Y/B Br/L B HEADLIGHT HEADLIGHT TAIL/BRAKE LIGHT TAIL/BRAKE LIGHT SUB-WIRE...
  • Page 153 WIRING DIAGRAM RS90N/RS90NR/RS90RS/RS90MS 2006 8FG-0F001-00/8GE-0F001-00 1 Pickup coil COLOR CODE 2 A.C. magneto B ..... Black 3 Rectifier/regulator Br .... Brown 4 Main switch Ch ... Chocolate 5 Load control relay Dg ... Dark green 6 Main fuse G ..... Green 7 Starter relay Gy ...
  • Page 154 WIRING DIAGRAM RS90GT 2006 8GG-0F001-00 (BLACK) G L/Y G/B Ch B Dg R/B B (BLACK) (BLACK) Lg/W B/W Y/W Br/W Lg Br/Y Y/R G Lg/L Y/B Br/L B HEADLIGHT HEADLIGHT TAIL/BRAKE LIGHT SUB-WIRE (BLACK) WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS...
  • Page 155 WIRING DIAGRAM RS90GT 2006 8GG-0F001-00 1 Pickup coil COLOR CODE 2 A.C. magneto B ..... Black 3 Rectifier/regulator Br .... Brown 4 Main switch Ch ... Chocolate 5 Load control relay Dg ... Dark green 6 Main fuse G ..... Green 7 Starter relay Gy ...
  • Page 156 YAMAHA MOTOR CO., LTD. PRINTED IN U.S.A. 2005.07 CR...

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