Yamaha TTR90 Manual

5 (1)
Yamaha TTR90 Manual

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 2006.04-0.3×1 CR (E,F,G)

OWNER’S MANUAL

TT-R90(W) TT-R90E(W)

3P2-28199-81-E0

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. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.

The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. 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.

AN IMPORTANT SAFETY MESSAGE:

READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR MOTORCYCLE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.

NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.

WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg (88 lb).

AN IMPORTANT NOTE TO PARENTS:

This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abilities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to operate the motorcycle safely.

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.

HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.

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.

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!

 

 

 

 

Failure to follow WARNING instructions could result in severe injury or death to the

 

WARNING

 

motorcycle operator, a bystander or a person inspecting or repairing the motor-

 

 

 

 

cycle.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A CAUTION indicates special precautions that must be taken to avoid damage to

 

CAUTION:

 

 

 

 

the motorcycle.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE:

A NOTE provides key information to make procedures easier or clearer.

 

 

 

 

 

NOTE:

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. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10030

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

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.

*Product and specifications are subject to change without notice.

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.

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 ........................

3-1

Shift pedal .......................................

3-2

Brake lever .....................................

3-2

Brake pedal ....................................

3-2

Fuel tank cap ..................................

3-3

Fuel .................................................

3-3

Fuel tank breather hose ..................

3-4

Fuel cock ........................................

3-5

Starter (choke) lever .......................

3-6

Kickstarter .......................................

3-6

Seat ................................................

3-7

Sidestand ........................................

3-7

Starting circuit cut-off system

 

[TT-R90E(W)]...............................

3-8

PRE-OPERATION CHECKS ..............

4-1

Pre-operation check list ..................

4-2

OPERATION AND IMPORTANT

 

RIDING POINTS.................................

5-1

Starting and warming up a

 

cold engine [TT-R90(W)] .............

5-1

Starting and warming up a

 

cold engine [TT-R90E(W)] ...........

5-2

Starting a warm engine ..................

5-2

Shifting ...........................................

5-3

Engine break-in ..............................

5-4

Parking [TT-R90(W)] .......................

5-4

Parking [TT-R90E(W)].....................

5-5

PERIODIC MAINTENANCE AND

 

MINOR REPAIR .................................

6-1

PERIODIC MAINTENANCE ...........

6-1

Owner’s tool kit ...............................

6-2

Periodic maintenance chart for

 

the emission control system .......

6-3

General maintenance and

 

lubrication chart ..........................

6-4

Removing and installing the

 

cowling and panel .......................

6-6

Checking the spark plug .................

6-7

Engine oil .......................................

6-8

Cleaning the air filter element ......

6-10

Cleaning the spark arrester ..........

6-12

Adjusting the carburetor ...............

6-13

Adjusting the engine idling

 

speed ........................................

6-13

Adjusting the throttle cable

 

free play ....................................

6-14

Valve clearance ...........................

6-14

Tires .............................................

6-15

Spoke wheels ..............................

6-16

Accessories and replacement

 

parts .........................................

6-16

Adjusting the brake lever

 

free play ....................................

6-17

Adjusting the brake pedal

 

free play ....................................

6-17

Checking the front and rear

 

brake shoes ..............................

6-18

Drive chain slack ..........................

6-18

Cleaning and lubricating the

 

drive chain ................................

6-20

Checking and lubricating the

 

cables .......................................

6-21

Checking and lubricating the

 

throttle grip and cable ...............

6-21

Checking and lubricating the

 

brake and shift pedals ..............

6-21

Checking and lubricating the

 

brake lever ................................

6-22

Checking and lubricating the

 

sidestand ..................................

6-22

Lubricating the swingarm

 

pivots ........................................

6-22

Checking the front fork .................

6-23

Checking the steering ..................

6-23

Checking the wheel bearings .......

6-24

Battery [TT-R90E(W)] ...................

6-24

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

SAFETY INFORMATION

EAU41860

Safe riding

Always make pre-operation

1checks. 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.

Many accidents involve inexperienced operators.

Make sure that the operator is qualified and that you only lend your motorcycle to other qualified operators.

Know your skills and limits. Staying within your limits may help you to avoid an accident.

Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or un-

dercornering (insufficient lean angle for the speed). Never travel faster than warranted by conditions.

Ride cautiously in unfamiliar areas. You may encounter hidden obstacles that could cause an accident.

The posture of the operator is important for proper control. The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.

Never ride under the influence of alcohol or other drugs.

Be sure the transmission is in neutral before starting the engine.

Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.

Always wear an approved helmet.

Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.

The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.

Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.

Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.

1-1

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. Here are some general guidelines to follow if adding accessories to your motorcycle:

Loading

The weight of the operator must not exceed 40 kg (88 lb).

Accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.

Shifting weights can create a sudden imbalance. Make sure that accessories are securely attached to the motorcycle before riding. Check accessory mounts frequently.

Never attach any large or heavy items to the handlebar, front fork, or front fender.

Accessories

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.

Keep these guidelines in mind for mounting accessories in addition to those provided under “Loading”.

Never install accessories or that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation.

Accessories fitted to the handlebar or the front fork area can create instability due to improper

1-2

weight distribution or aerodynamic changes. If accessories are added to the handlebar or

front fork area, they must be as 1 lightweight as possible and should be kept to a minimum.

Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds.

Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended.

Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of engine power.

SAFETY INFORMATION

Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMABLE:

1• 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. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.

Always turn the engine off before leaving the motorcycle unattended. For models equipped with a main switch: Remove the key from the main switch. When parking the motorcycle, note the following:

The engine and exhaust pipe(s)/ muffler(s) may be hot, therefore, park the motorcycle in a place

where pedestrians or children are not likely to touch these hot areas.

Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.

Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire.

When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel cock(s) are turned to “ON” or “RES” (for vacuum type)/“OFF” (for manual type). If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.

If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.

1-3

SAFETY INFORMATION

EAU41370

Location of important labels

Please read the following important labels carefully before operating this vehicle.

For Canada

1

 

 

1-4

SAFETY INFORMATION

For Canada

 

1

 

1

 

 

2

 

 

 

TIRE INFOMATION

 

 

 

 

 

 

 

 

 

 

Cold tire normal pressure should be set as

 

 

 

 

follows.

 

 

 

 

FRONT : 100kPa, {1.00kgf/cm2}, 15psi

 

 

 

 

REAR

: 100kPa, {1.00kgf/cm2}, 15psi

 

 

 

 

 

3RV-21668-A0

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

3RV-21668-B0

3

4

 

WARNING

BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS.

NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger.

NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You can collide with another vehicle if you operate this vehicle on a public road. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET,

eye protection, and protective clothing.

3PT-2118K-A0

5

AVERTISSEMENT

LIRE LE MANUEL DU PROPRIETAIRE ANSI QUE TOUTES LES ETIQUETTES AVANT D’UTILISER CE VEHICULE.

NE JAMAIS TRANSPORTER DE PASSAGER. La conduite avec passager augmente les risques de perte de contrôle.

NE JAMAIS ROULER SUR DES CHEMINS PUBLICS. Vous pourriez entrer en collision avec un aulre véhicule. TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE APPROUVE, des lunettes et des vêlements de protection.

3PT-2118K-B0

1-5

SAFETY INFORMATION

Except for Canada

1

1-6

SAFETY INFORMATION

Except for Canada

1 1

TIRE INFORMATION

Cold tire normal pressure should be set as follows.

FRONT : 100kPa, {1.00kgf/cm2}, 15psi REAR : 100kPa, {1.00kgf/cm2}, 15psi

3RV-21668-A0

2

YAMAHA MOTOR CO., LTD.

SHIZUOKA JAPAN

YAMAHA

4GB-2155A-00

3

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.

Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.

Antes de conducir este vehículo, lea el Manual del Propietario.

5PA-21568-00

5

1-7

DESCRIPTION

EAU10410

Left view

2

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)

2-1

DESCRIPTION

EAU10420

Right view

2

1.Spark arrester (page 6-12)

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.Spark plug cap (page 6-7)

8.Brake pedal (page 3-2)

9. Engine oil filler cap (page 6-8)

2-2

DESCRIPTION

EAU10430

Controls and instruments

2

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)

2-3

INSTRUMENT AND CONTROL FUNCTIONS

EAU40340

Main switch [TT-R90E(W)]

3

The main switch controls the ignition system. The main switch positions are described below.

EAU10630

ON

All electrical systems are supplied with power, and the engine can be started. The key cannot be removed.

EAU10660

OFF

All electrical systems are off. The key can be removed.

Handlebar switches

Left

1. Engine stop switch “ /

Right [TT-R90E(W)]

1. Start switch “

EAU12346

EAU41890

Engine stop switch “

/ ”

[TT-R90(W)]

Set this switch to “ ” before starting the engine. Set this switch to “” to stop the engine.

EAU12660

Engine stop switch “ /” [TT-R90E(W)]

Set this switch to “ ” before starting the engine. Set this switch to “” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.

EAU12710

Start switch “” [TT-R90E(W)]

Push this switch to crank the engine with the starter.

ECA10050

CAUTION:

See page 5-2 for starting instructions prior to starting the engine.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

EAU39850

EAU12890

EAU12941

Shift pedal

Brake lever

Brake pedal

3

1. Shift pedal

This motorcycle is equipped with a con- stant-mesh 3-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position.

1. Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.

1. Brake pedal

The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

EAU13180

EAU13211

 

 

ECA10070

Fuel tank cap

Fuel

 

 

CAUTION:

 

 

3

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.

EWA11090

WARNING

Make sure that the fuel tank cap is properly closed before riding.

1.Fuel tank filler tube

2.Fuel level

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

EWA10880

WARNING

Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands.

Avoid spilling fuel on the hot engine.

Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.

EAU41930

For Canada

Recommended fuel:

REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:

4.2 L (1.11 US gal) (0.92 Imp.gal)

Fuel reserve amount:

0.5 L (0.13 US gal) (0.11 Imp.gal)

ECA11400

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number

3-3

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%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

For Europe, Oceania and South Africa

Recommended fuel:

For Europe: REGULAR UNLEADED GASOLINE ONLY

For Oceania and South Africa: UNLEADED GASOLINE ONLY

Fuel tank capacity:

4.2 L (1.11 US gal) (0.92 Imp.gal)

Fuel reserve amount:

0.5 L (0.13 US gal) (0.11 Imp.gal)

ECA11400

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with 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 costs.

EAU13411

Fuel tank breather hose

TT-R90(W)

3

1. Fuel tank breather hose

TT-R90E(W)

1. Fuel tank breather hose

Before operating the motorcycle:

Check the fuel tank breather hose connection.

3-4

Loading...
+ 57 hidden pages