Related Manuals for Yamaha TT-R90(W)
Summary of Contents for Yamaha TT-R90(W)
- Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG TT-R90(W) TT-R90E(W) 3P2-28199-81...
- Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2006.04-0.3×1 CR AUF RECYCLINGPAPIER GEDRUCKT (E,F,G)
- Page 3 OWNER’S MANUAL TT-R90(W) TT-R90E(W) 3P2-28199-81-E0...
- Page 5 Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
- Page 6 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.
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Page 7: Important Manual Information
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. - Page 8 IMPORTANT MANUAL INFORMATION EWA14350 WARNING THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPER- ATE 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.
- Page 9 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.
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Page 10: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Valve clearance ......6-14 Location of important labels ....1-4 RIDING POINTS......... 5-1 Tires ..........6-15 Starting and warming up a Spoke wheels ......6-16 DESCRIPTION ........2-1 cold engine [TT-R90(W)] ..... 5-1 Accessories and replacement Left view ..........2-1 Starting and warming up a... - Page 11 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 ..........7-1 Care ..........7-1 Storage [TT-R90(W)] .......7-3 Storage [TT-R90E(W)].....7-4 SPECIFICATIONS ......8-1 CONSUMER INFORMATION.....9-1 Identification numbers ....9-1...
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Page 12: Safety Information
Modifications made to this motorcycle Staying within your limits may cycle accidents are the result of head not approved by Yamaha, or the re- help you to avoid an accident. injuries. The use of a safety helmet is moval of original equipment, may ren-... - Page 13 Since Yamaha cannot • Bulky or large accessories may your motorcycle. Use extra care when test all other accessories that may be...
- Page 14 SAFETY INFORMATION Gasoline and exhaust gas where pedestrians or children GASOLINE IS HIGHLY FLAMMA- are not likely to touch these hot BLE: areas. • Always turn the engine off when • Do not park the motorcycle on a refueling. slope or soft ground, otherwise it •...
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Page 15: Location Of Important Labels
SAFETY INFORMATION EAU41370 Location of important labels Please read the following important labels carefully before operating this vehicle. For Canada... - Page 16 SAFETY INFORMATION For Canada INFORMATION SUR LES PNEUS TIRE INFOMATION La pression des pneus à froid doit normalement Cold tire normal pressure should be set as être réglée comme suit. follows. AVANT : 100kPa, {1.00kgf/cm }, 15psi FRONT : 100kPa, {1.00kgf/cm }, 15psi ARRIERE : 100kPa, {1.00kgf/cm }, 15psi...
- Page 17 SAFETY INFORMATION Except for Canada...
- Page 18 SAFETY INFORMATION Except for Canada TIRE INFORMATION Cold tire normal pressure should be set as follows. YAMAHA MOTOR CO., LTD. FRONT : 100kPa, { 1.00kgf/cm } , 15psi SHIZUOKA JAPAN REAR : 100kPa, {1.00kgf/cm }, 15psi 3RV-21668-A0 YAMAHA 4GB-2155A-00 Before you operate this vehicle, read the owner’s manual.
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Page 19: Description
DESCRIPTION EAU10410 Left view 1. Fuel cock (page 3-5) 2. Starter (choke) lever (page 3-6) 3. Battery [TT-R90E(W)] (page 6-24) 4. Engine oil drain bolt (page 6-8) 5. Shift pedal (page 3-2) 6. Throttle stop screw (page 6-13) -
Page 20: Right View
DESCRIPTION EAU10420 Right view 1. Spark arrester (page 6-12) 9. Engine oil filler cap (page 6-8) 2. Seat (page 3-7) 3. Kickstarter (page 3-6) 4. Fuse [TT-R90E(W)] (page 6-26) 5. Fuel tank (page 3-3) 6. Air filter element (page 6-10) 7. -
Page 21: Controls And Instruments
DESCRIPTION EAU10430 Controls and instruments 1. Left handlebar switch (page 3-1) 2. Brake lever (page 3-2) 3. Throttle grip (page 6-14) 4. Right handlebar switch [TT-R90E(W)] (page 3-1) 5. Fuel tank cap (page 3-3) 6. Main switch [TT-R90E(W)] (page 3-1) -
Page 22: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS EAU40340 EAU12346 EAU41890 Main switch [TT-R90E(W)] Handlebar switches Engine stop switch “ ” [TT-R90(W)] Left Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine. EAU12660 Engine stop switch “... -
Page 23: Shift Pedal
INSTRUMENT AND CONTROL FUNCTIONS EAU39850 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal This motorcycle is equipped with a con- The brake lever is located at the right The brake pedal is on the right side of stant-mesh 3-speed transmission. -
Page 24: Fuel Tank Cap
Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a pump octane number... -
Page 25: Fuel Tank Breather Hose
Use of un- taining methanol is not recommended leaded fuel will extend spark plug life TT-R90E(W) by Yamaha because it can cause dam- and reduce maintenance costs. age to the fuel system or vehicle perfor- mance problems. -
Page 26: Fuel Cock
INSTRUMENT AND CONTROL FUNCTIONS Check the fuel tank breather hose EAU13561 Fuel cock for cracks or damage, and replace The fuel cock supplies fuel from the it if damaged. tank to the carburetor while filtering it al- Make sure that the end of the fuel tank breather hose is not blocked, The fuel cock has three positions: and clean it if necessary. -
Page 27: Starter (Choke) Lever
INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13590 EAU13680 Starter (choke) lever “ ” Kickstarter fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON”... -
Page 28: Seat
INSTRUMENT AND CONTROL FUNCTIONS EAU41600 EAU37490 Seat Sidestand The sidestand is located on the left side To remove the seat of the frame. Raise the sidestand or Remove the nuts, and then pull the seat lower it with your foot while holding the off. -
Page 29: Starting Circuit Cut-Off System [Tt-R90E(W)]
Periodically check the operation of the starting circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system be- fore riding. - Page 30 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 6. Shift the transmission into the neutral position. 7. Push the start switch. Does the engine start? The neutral switch may be defective.
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Page 31: Pre-Operation Checks
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. -
Page 32: Pre-Operation Check List
• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-14, 6-21 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-21 •... - Page 33 PRE-OPERATION CHECKS ITEM CHECKS PAGE • Make sure that operation is smooth. Brake pedal 6-21 • Lubricate pedal pivoting point if necessary. • Make sure that operation is smooth. Brake lever 6-22 • Lubricate lever pivoting point if necessary. • Make sure that operation is smooth. Sidestand 6-22 •...
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Page 34: Operation And Important Riding Points
EWA14410 WARNING before riding. Consult a Yamaha dealer regarding any control or Be sure to shift the transmis- function that you do not thor- sion into neutral before starting oughly understand. -
Page 35: Starting And Warming Up A Cold Engine [Tt-R90E(W)]
OPERATION AND IMPORTANT RIDING POINTS EAU40090 ECA11130 EAU16640 Starting and warming up a Starting a warm engine CAUTION: cold engine [TT-R90E(W)] Follow the same procedure as for start- For maximum engine life, always ing a cold engine with the exception 1. -
Page 36: Shifting
OPERATION AND IMPORTANT RIDING POINTS EAU39901 ECA15441 ECA15460 Shifting CAUTION: CAUTION: Even with the transmission in Always close the throttle before the neutral position, do not shifting gears, otherwise damage to coast for long periods of time the engine and drive train may re- with the engine off, and do not sult. -
Page 37: Engine Break-In
5 ans or children are not likely to immediately have a Yamaha dealer hours of operation. The various parts in touch them. check the vehicle. -
Page 38: Parking [Tt-R90E(W)]
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 Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them. -
Page 39: Periodic Maintenance And Minor Repair
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU40350 render the vehicle unsafe for use. PERIODIC MAINTENANCE Consult a Yamaha dealer before at- Safety is an obligation of the owner. Pe- PROPER PERIODIC MAINTENANCE tempting any changes. riodic inspection, adjustment and lubri-... -
Page 40: Owner's Tool Kit
NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EWA10340 WARNING Modifications approved Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use. -
Page 41: Periodic Maintenance Chart For The Emission Control System
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. -
Page 42: General Maintenance And Lubrication Chart
7 * Swingarm pivot bearings • Moderately repack with lithium-soap-based grease. • Check chain slack/alignment and condition. Drive chain • Adjust and lubricate chain with Yamaha chain and cable Every ride lube thoroughly. • Check bearing assemblies for looseness. √... - Page 43 • Replace if necessary. Shock absorber assem- • Check operation and for oil leakage. √ 16 * • Replace if necessary. • Apply Yamaha chain and cable lube or engine oil 10W-30 √ √ √ 17 * Control cables thoroughly.
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Page 44: Removing And Installing The Cowling And Panel
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18740 EAU19193 Removing and installing the Panel A cowling and panel To remove the panel Remove the bolts, and then take the panel off. 1. Bolt 2. Cowling A To install the cowling 1. Panel A 2. -
Page 45: Checking The Spark Plug
If the spark plug shows a distinctly dif- ferent color, the engine could be oper- ating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check 1. Spark plug cap 1. Spark plug gap the vehicle. -
Page 46: Engine Oil
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Clean the surface of the spark plug EAU39840 Engine oil gasket and its mating surface, and The engine oil level should be checked then wipe off any grime from the before each ride. In addition, the oil spark plug threads. - Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR To change the engine oil 5. Add the specified amount of the 7. Turn the engine off, and then 1. Start the engine, warm it up for recommended engine oil, and then check the oil level and correct it if several minutes, and then turn it install and tighten the engine oil fill- necessary.
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Page 48: Cleaning The Air Filter Element
NOTE: The sponge material should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other 1. Air filter case cover quality foam air filter oil 2. Screw 7. Insert the mesh and the sponge 3. - Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR 2. If dirt or water is visible, remove the hoses, clean them, and then reinstall them. 1. Spark plug cable ECA15571 CAUTION: 9. Install the panel. Make sure that the mesh and the sponge material are properly To clean the air filter check hose seated in the air filter case.
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Page 50: Cleaning The Spark Arrester
PERIODIC MAINTENANCE AND MINOR REPAIR EAU41230 3. Insert the tailpipe into the muffler, Cleaning the spark arrester and then install and tighten the The spark arrester should be cleaned bolt. at the intervals specified in the periodic NOTE: maintenance and lubrication chart. Make sure to align the bolt hole when EWA10980 WARNING... -
Page 51: Adjusting The Carburetor
Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart. -
Page 52: Adjusting The Throttle Cable Free Play
To prevent this nut in direction (b). from occurring, the valve clearance 3. Tighten the locknut. must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Throttle cable free play adjusting nut 2. -
Page 53: Tires
CHENG SHIN/KNOBBY glass fragments in it, or if the sidewall is Rear tire: temperature). cracked, have a Yamaha dealer re- Size: The tire air pressure must be ad- place the tire immediately. 3.00-12 4PR... -
Page 54: Spoke Wheels
If any dam- curely mounted to maintain the in- It is not recommended to patch age is found, have a Yamaha herent stability of the original a punctured tube. If unavoid- dealer replace the wheel. -
Page 55: Adjusting The Brake Lever Free Play
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22120 3. If the specified brake lever free EAU39811 Adjusting the brake lever free Adjusting the brake pedal free play could be obtained as de- play play scribed above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. -
Page 56: Checking The Front And Rear Brake Shoes
To remove the rear wheel: See less than 1.5 mm (0.06 in), have a on the motorcycle. page 6-28. Yamaha dealer replace the brake 2. Shift the transmission into the neu- shoes as a set. tral position. Front NOTE: 3. - Page 57 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Drive chain slack 1. Brake pedal free play adjusting nut 1. Axle nut 2. Locknut 2. Drive chain slack adjusting nut 4. If the drive chain slack is incorrect, 3. Drive chain slack adjusting nut 3.
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Page 58: Cleaning And Lubricating The Drive Chain
1. Remove all dirt and mud from the drive chain with a brush or cloth. NOTE: For a thorough cleaning, have a Yamaha dealer remove the drive chain and soak it in solvent. 2. Spray Yamaha Chain and Cable Lube or a high-quality spray-type... -
Page 59: Checking And Lubricating The Cables
If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE) -
Page 60: Checking And Lubricating The Brake Lever
Recommended lubricant: necessary. Lithium-soap-based grease Recommended lubricant: EWA10730 Lithium-soap-based grease (all-pur- WARNING pose grease) If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-22... -
Page 61: Checking The Front Fork
Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage. there is no danger of it falling over. have a Yamaha dealer check or re- pair it. To check the operation 2. Hold the lower ends of the front 1. -
Page 62: Checking The Wheel Bearings
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. - Page 63 To charge the battery To charge a sealed-type (MF) Have a Yamaha dealer charge the bat- battery, a special (constant-volt- tery as soon as possible if it seems to age) battery charger is required.
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Page 64: Replacing The Fuse [Tt-R90E(W)]
A strong wooden devices operate. box can be placed under the engine for 4. If the fuse immediately blows added stability. again, have a Yamaha dealer 1. Fuse check the electrical system. To service the front wheel 2. Spare fuse 1. -
Page 65: Front Wheel
EAU41810 To remove the front wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Axle nut of it falling over. -
Page 66: Rear Wheel
(See page 6-17.) WARNING 6. While applying the front brake, NOTE: It is advisable to have a Yamaha push down hard on the handlebar Make sure that the slot in the brake dealer service the wheel. several times to check for proper... - Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the brake pedal free play EAU41651 To install the rear wheel adjusting nut, and then disconnect 1. Install the drive chain onto the rear the brake rod at the brake cam- sprocket. shaft lever. 2.
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Page 68: Troubleshooting
However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. -
Page 69: Troubleshooting Chart [Tt-R90(W)]
Wipe off with a dry cloth and correct the the kickstarter. spark plug gap, or replace the spark plug. Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Have a Yamaha dealer check the vehicle. 6-31... -
Page 70: Troubleshooting Chart [Tt-R90E(W)]
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good. -
Page 71: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE EAU40461 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water. - Page 72 NOTE: 6. Touch up minor paint damage salt. Consult a Yamaha dealer for advice on caused by stones, etc. what products to use. 2. Apply a corrosion protection spray 7. Wax all painted surfaces.
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Page 73: Storage [Tt-R90(W)]
MOTORCYCLE CARE AND STORAGE EAU40651 3. Drain the carburetor float chamber EWA10950 Storage [TT-R90(W)] WARNING by loosening the drain bolt; this will prevent fuel deposits from building To prevent damage or injury from Short-term up. Pour the drained fuel into the sparking, make sure to ground the Always store your motorcycle in a cool, fuel tank. -
Page 74: Storage [Tt-R90E(W)]
MOTORCYCLE CARE AND STORAGE EAU26150 3. Drain the carburetor float chamber EWA10950 Storage [TT-R90E(W)] WARNING by loosening the drain bolt; this will prevent fuel deposits from building To prevent damage or injury from Short-term up. Pour the drained fuel into the sparking, make sure to ground the Always store your motorcycle in a cool, fuel tank. - Page 75 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.
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Page 76: Specifications
SPECIFICATIONS Dimensions: Weight: (NZL)(PRT)(SWE)(ZAF) TT-R90E YAMALUBE 4, SAE10W30 or Overall length: With oil and fuel: SAE20W40 (CAN) TT-R90 1525 mm (60.0 in) TT-R90 64.0 kg (141 lb) (AUS)(AUT)(BEL)(CHE)(DEU)(DNK)(ESP TT-R90E 67.0 kg (148 lb) Engine: )(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR) -20 -10 10 20 30 40 50 ˚C (NZL)(PRT)(SWE)(ZAF) Engine type: SAE 10W-30... - Page 77 SPECIFICATIONS Fuel: Transmission: Rear tire: Recommended fuel: Primary reduction system: Type: TT-R90 Regular unleaded gasoline only Spur gear With tube (AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP Primary reduction ratio: Size: )(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR) 67/18 (3.722) 3.00-12 4PR (PRT)(SWE)(ZAF) Secondary reduction system: Manufacturer/model: TT-R90 Unleaded gasoline only Chain drive CHENG SHIN/KNOBBY (AUS)(NZL) Secondary reduction ratio:...
- Page 78 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: Battery: Model: TT-R90E GT4B-5 Voltage, capacity:...
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Page 79: Consumer Information
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: TT-R90E(W) 1. - Page 80 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.
- Page 81 INDEX Fuel tank cap...........3-3 Starting and warming up a cold engine Fuse, replacing [TT-R90E(W)] ....6-26 [TT-R90E(W)] ........5-2 Accessories and replacement parts ..6-16 Starting and warming up a cold engine Air filter element, cleaning ....6-10 [TT-R90(W)].......... 5-1 Handlebar switches .........3-1 Starting circuit cut-off system Battery [TT-R90E(W)] ......
- Page 82 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.04-0.3×1 CR...