Yamaha TTR90 User Manual
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
TT-R90(W)
TT-R90E(W)
3P2-28199-81
PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
AUF RECYCLINGPAPIER GEDRUCKT
YAMAHA MOTOR CO., LTD.
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 UNDER-
STAND 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
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
EAU41090
WARNING
Failure to follow WARNING instructions could result in severe injury or death
motorcycle operator, a bystander or a person inspecting or repairing the motor-
to the
cycle.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
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
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
TABLE OF CONTENTS
SAFETY INFORMATION
Safe riding
● Always make pre-operation
1
checks. Careful checks may help
prevent an accident.
● This motorcycle is designed for off-
road 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 car-
ry the operator only. No passen-
gers.
● Many accidents involve inexperi-
enced 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-
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dercornering (insufficient lean angle for the speed). Never travel
faster than warranted by conditions.
● Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an accident.
● The posture of the operator is im-
portant 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 neu-
tral 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 sud-
den 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 suspen-
sion travel, steering travel or con-
trol 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
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 electri-
cal 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.
1
SAFETY INFORMATION
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMA-
BLE:
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 gaso-
line, 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
Location of important labels
Please read the following important labels carefully before operating this vehicle.
For Canada
SAFETY INFORMATION
EAU41370
1
1-4
SAFETY INFORMATION
For Canada
1
1
TIRE INFOMATION
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm2}, 15psi
REAR : 100kPa, {1.00kgf/cm
2
}, 15psi
3RV-21668-A0
3
5
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.
AVERTISSEMENT
3PT-2118K-B0
2
INFORMATION SUR LES PNEUS
La pression des pneus à froid doit normalement
être réglée comme suit.
AVANT : 100kPa, {1.00kgf/cm
ARRIERE
: 100kPa, {1.00kgf/cm2}, 15psi
4
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.
2
}, 15psi
WARNING
3RV-21668-B0
3PT-2118K-A0
1-5
Except for Canada
SAFETY INFORMATION
1
1-6
SAFETY INFORMATION
Except for Canada
1
1
Cold tire normal pressure should be set as
follows.
FRONT : 100kPa, {1.00kgf/cm
REAR : 100kPa, {1.00kgf/cm
TIRE INFORMATION
2
}
, 15psi
2
}, 15psi
3RV-21668-A0
3
2
YAMAHA MOTOR CO., LTD.
SHIZUOKA JAPAN
YAMAHA
4GB-2155A-00
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
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)
DESCRIPTION
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2
2-1
DESCRIPTION
Right view
2
EAU10420
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
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)
DESCRIPTION
EAU10430
2
2-3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch [TT-R90E(W)]
3
The main switch controls the ignition
system. The main switch positions are
described below.
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
OFF
All electrical systems are off. The key
can be removed.
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EAU10630
EAU10660
Handlebar switches
Left
1. Engine stop switch “ / ”
Right [TT-R90E(W)]
1. Start switch “”
EAU12346
Engine stop switch “ / ”
EAU41890
[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
Shift pedal
1. Shift pedal 1. Brake lever 1. Brake pedal
This motorcycle is equipped with a constant-mesh 3-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom po-
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
EAU12890
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
sition.
EAU12941
3
3-2
INSTRUMENT AND CONTROL FUNCTIONS
EAU13180
Fuel tank cap
Fuel
3
1. Fuel tank cap 1. Fuel tank filler tube
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 clock-
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.
wise.
EWA11090
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
WARNING
● Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot en-
gine.
EAU13211
EWA10880
ECA10070
CAUTION:
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.
3-3
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
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
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