YAMAHA TTR90ER, TTR90E PARTS CATALOGUE 03

TTR90ER

TTR90E

TTR90ER

TTR90ER

(5HNE)

(5HNF)

(5HNF)

(5HNG)

USA

EUROPE,S.AFRICA

OCEANIA

CANADA

1B5HN−100EA

TTR90E/TTR90ER

PARTS CATALOGUE E2002 by Yamaha Motor Co., Ltd.

1st Edition, Oct. 2002 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited. Printed in Japan

A3

A4

FOREWORD

This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.

TTR90ER(5HNE/5HNF/5HNG),TTR90E(5HNF)

1.Modifications or additions which have been made after issue of the Parts Catalogue will be announced in the Yamaha Parts News.

It is advisable that you make necessary corrections to the Parts Catalogue according to the Yamaha Parts News.

2.Abbreviations

The Following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number. “UN” Use as many as needed. “AP” Alternate Parts

“LM” Local Made (Parts need to be ordered locally) “F#” Frame No. (Applicable machine No.)

3.Parts, which are to be supplied in an assembly, are listed with a dot(.) in front of the part name as shown below.

EXAMPLE CARBURETOR ASSY

.JET, PILOT

.NOZZLE, MAIN

4.Number of component for assembly

The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit.

EXAMPLE

PART NO.	DESCRIPTION	Q’TY REMARKS
2F5−83310−60	FRONT FLASHER LIGHT ASSY	2
115−83311−60	.BULB (6V−18W)	1
1M1−83309−60	.REFLECTOR	1

5.Applicable colors of graphics are represented in the “REMARKS” as shown below.

PART NO.	DESCRIPTION	Q’TY	REMARKS
2N4−24110−00−X5 FUEL TANK COMP.		1	MXR
3J1−24240−10	.GRAPHIC, FUEL TANK	1	FOR MXR

6. Applicable Serial No.
Engine Serial No.	Frame Serial No.

7.Note that the illustrations for reference in finding parts numbers, not to be used for assembling. When assembling, please use the applicable service manual.

8.The asterisk (*) before a reference number indicates modification items after the first edition.

A5

MODEL LABEL

(1)A label called “Model Label” is affixed in the location as indicated in (3) below. When using this parts catalogue, please be sure to cross−refer the “model code − production code No.” in the catalogue to the “model code − production code No. “indicated on the Model Label affixed onto the product concemed.

(2)“Model Label”Indication

a	b	a:	Model Type Code
xxxx – xxx		b:	Production Code No.	4TW1–010
x	c	c:	Colouring Type	A

(3) Model Label Affixing Location

(4) Model Code − Production Code Number of Model Listed in This Parts Catalog

	Model	Production	Country
	Code	Code No.	(destination)
	5HNE	010	USA
		010	FRANCE
			AUSTRALIA
		020	NEW ZEALAND
			SOUTH AFRICA
		030	AUSTRIA
			GERMANY
	5HNF	040	BELGIUM
			HOLLAND
		050	SWITZERLAND
			DENMARK
		060	FINLAND
			IRELAND
			NORWAY
		070	SPAIN

	Model	Production	Country
	Code	Code No.	(destination)
		080	ENGLAND
	5HNF	090	GREECE
		100	PORTUGAL
		110	SWEDEN
	5HNG	010	CANADA

(5) Coloring Information

	Model	Colouring type	Colour	Colour Name	Abbrevi-
	Code	code	code		ation
	5HNE			DEEP PURPLISH BLUE
	5HNF	A	0583		DPBSE
				SOLID E
	5HNG

A6

ENGINE

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 CRANKSHAFT. PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 CAMSHAFT. CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6 INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8 EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10 CRANKCASE COVER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12 STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B15 SHIFT CAM. FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2 SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3

CHASSIS

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4 FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5 SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6 REAR ARM. SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . C7 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C8 FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C13 FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C14 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C15 STEERING HANDLE. CABLE . . . . . . . . . . . . . . . . . . . . . . . . . D3

CONTENTS

STAND. FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

HANDLE SWITCH. LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . D7

ELECTRICAL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8

INDEX

NUMERICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M1

FIG. 1 CYLINDER HEAD

REF.		PART NO.	DESCRIPTION
NO.
1	4GL−11110−11		CYLINDER HEAD ASSY
2	4GL−11134−10		.GUIDE, EXHAUST VALVE
3	93210−09418		.O−RING
4	22F−14651−00		.BOLT, STUD
5	50M−11185−01		COVER, CYLINDER HEAD SIDE 1
6	93210−63556		O−RING
7	98507−06016		SCREW, PAN HEAD
8	22F−11186−00		COVER, CYLINDER HEAD SIDE 2
9	93210−44704		O−RING
10	90201−08609		WASHER, PLATE
11	90176−08026		NUT, CROWN
12	94701−00372		PLUG SPARK (NGK CR6HSA)
	94701−00283		PLUG, SPARK (ND U20FSR−U)
13	4GL−11181−00		GASKET, CYLINDER HEAD 1
14	99530−10114		PIN, DOWEL
15	95027−06085		BOLT, FLANGE
16	90105−06004		BOLT, FLANGE
17	4GL−11311−01		CYLINDER 1
18	5HN−11351−00		GASKET, CYLINDER
19	90465−08230		CLAMP

B2

5HNE	5HNF	5HNG
1	1	1
2	2	2
2	2	2
2	2	2
1	1	1
1	1	1
2	2	2
2	2	2
2	2	2
4	4	4
4	4	4
1	1	1
1	1	1
1	1	1
2	2	2
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1

REMARKS

UR

UR

FIG. 2 CRANKSHAFT. PISTON

REF.		PART NO.	DESCRIPTION
NO.
1	5HN−11400−01		CRANKSHAFT ASSY
2	5HN−W1141−00		.CRANK 1
3	4GL−11681−10		.PIN, CRANK 1
4	93310−326M9		.BEARING
5	4GL−11651−01		.ROD, CONNECTING
6	5HN−11422−00		.CRANK 2
7	5DV−11445−00		.SPACER
8	93306−20590		.BEARING
9	90280−03017		KEY, WOODRUFF
10	4GL−11445−00		SPACER
11	4GL−11631−01		PISTON (STD)
	4GL−11636−01		PISTON (0.50MM O/S)
	4GL−11638−01		PISTON (1.00MM O/S)
12	22K−11633−01		PIN, PISTON
13	93450−14088		CIRCLIP
14	22K−11610−01		PISTON RING SET (STD)
	22K−11610−21		PISTON RING SET (0.50MM O/S)
	22K−11610−41		PISTON RING SET (1.00MM O/S)

B3

5HNE	5HNF	5HNG
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
2	2	2
1	1	1
1	1	1
1	1	1

REMARKS

AP

AP

AP

AP

FIG. 3 VALVE

REF.		PART NO.	DESCRIPTION
NO.
1	4GL−12111−11		VALVE, INTAKE
2	4GL−12121−01		VALVE, EXHAUST
3	1WG−12119−00		SEAL, VALVE STEM
4	5DV−12114−01		SPRING, VALVE OUTER
5	1WG−12118−00		COTTER, VALVE
6	3UH−12117−00		RETAINER, VALVE SPRING
7	22F−12151−00		ARM, VALVE ROCKER
8	22F−12159−00		SCREW, VALVE ADJUSTING
9	90170−05302		NUT
10	22F−12156−00		SHAFT, ROCKER 2

B4

5HNE	5HNF	5HNG
1	1	1
1	1	1
2	2	2
2	2	2
4	4	4
2	2	2
2	2	2
2	2	2
2	2	2
2	2	2

REMARKS

FIG. 4 CAMSHAFT. CHAIN

REF.		PART NO.	DESCRIPTION
NO.
1	5HN−12170−00		CAMSHAFT ASSY 1
2	4GL−1111F−00		PLATE
3	90110−06226		BOLT, HEXAGON SOCKET HEAD
4	4GL−12176−00		SPROCKET, CAM CHAIN
5	90201−08326		WASHER, PLATE
6	90101−08590		BOLT
7	94591−51084		CHAIN
8	4GL−12231−00		GUIDE, STOPPER 1
9	4GL−12241−00		GUIDE, STOPPER 2
10	90110−06091		BOLT, HEXAGON SOCKET HEAD
11	4GL−12210−00		TENSIONER ASSY, CAM CHAIN
12	4RF−12213−00		GASKET, TENSIONER CASE
13	90430−06014		GASKET
14	91317−06016		BOLT

B5

5HNE	5HNF	5HNG
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
2	2	2
1	1	1
1	1	1
2	2	2
2	2	2

REMARKS

FIG. 5 OIL PUMP

REF.		PART NO.	DESCRIPTION
NO.
1	4GL−13300−01		OIL PUMP ASSY
2	4GL−13325−00		.GEAR, PUMP DRIVEN (34T)
3	99001−05600		.CIRCLIP
4	90208−07052		.WASHER, CONICAL SPRING
5	22F−13329−01		GASKET, PUMP COVER
6	90155−06007		SCREW, FLAT FILLISTER
7	90340−12001		PLUG, STRAIGHT SCREW
8	812−11198−00		GASKET
9	22F−13411−01		STRAINER, OIL
10	4GL−13324−00		GEAR, PUMP DRIVE
11	4GL−13451−01		FILTER,ROTARY

B6

5HNE	5HNF	5HNG
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
2	2	2
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1

REMARKS

FIG. 6 INTAKE

REF.		PART NO.	DESCRIPTION
NO.
1	5HN−13586−10		JOINT, CARBURETOR 1
2	4GL−13595−00		JOINT
3	93210−25552		O−RING
4	91317−06035		BOLT
5	91317−06025		BOLT
6	5HN−14411−00		CASE, AIR CLEANER 1
7	5HN−14412−00		CAP, CLEANER CASE 1
8	5HN−14472−00		PLATE, ELEMENT
9	5HN−14451−00		ELEMENT, AIR CLEANER
10	5HN−14437−00		DUCT
11	5HN−14453−00		JOINT, AIR CLEANER 1
12	12R−14452−00		SEAL
13	59V−14457−00		SEAL
14	90467−22080		CLIP
15	98507−06025		SCREW, PAN HEAD
16	92907−06600		WASHER, PLATE
17	90159−06056		SCREW, WITH WASHER
18	5TN−E3575−00		BAND

B7

5HNE	5HNF	5HNG
1	1	1
1	1	1
2	2	2
2	2	2
2	2	2
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
3	3	3
3	3	3
2	2	2
1	1	1

REMARKS

FIG. 7 CARBURETOR

REF.		PART NO.	DESCRIPTION
NO.
1	5HN−14101−01		CARBURETOR ASSY 1
2	4GL−14239−00		.SEAL
3	18A−14143−18		.JET, MAIN (# 90)
4	5HN−14141−13		.NOZZLE, MAIN
5	5HN−1490J−00		.NEEDLE SET
6	3KD−14142−12		.JET, PILOT (# 12.5)
7	7LG−14150−11		.NEEDLE ASSY
8	353−14186−00		.PIN, FLOAT
9	4GL−14104−00		.AIR SCREW SET
10	12R−14191−00		.PLUG, DRAIN
11	98507−04014		.SCREW, PAN HEAD
12	92907−04100		.WASHER, SPRING
13	4GL−14103−00		.THROTTLE SCREW SET
14	5HN−14985−00		.FLOAT
15	4GL−1410A−00		.STARTER SET
16	5HN−14135−00		..SPRING, PLUNGER
17	5HN−14112−25		.VALVE, THROTTLE 1
18	241−14147−00		.O−RING
19	4GL−14348−00		.PIPE 1
20	5HN−14987−00		.HOSE
21	98507−04012		.SCREW, PAN HEAD
22	92907−04100		.WASHER, SPRING
23	4NM−14275−00		.SPRING
24	4NM−14198−00		.GASKET
25	5HN−14148−00		.PIPE
26	522−14161−00		.NUT, CABLE ADJUSTING

B8

5HNE	5HNF	5HNG
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
4	4	4
4	4	4
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
1	1	1
2	2	2
2	2	2
1	1	1
1	1	1
1	1	1
1	1	1

REMARKS