YAMAHA TTR90ER, TTR90E PARTS CATALOGUE 03

TTR90ER

(5HNE)

USA

TTR90E
TTR90ER
TTR90ER

(5HNF)

(5HNF)

(5HNG)

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

HNF

HNF

(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

ab

xxxx – xxx

c

x

(3) Model Label Affixing Location

a: Model Type Code

b: Production Code No.

c: Colouring Type

4TW1–010

A

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

Model

Code

5HNE 010 USA 080 ENGLAND

5

Production

Code No.

010 FRANCE

020

030

040

050

060

Country

(destination)

AUSTRALIA

NEW ZEALAND

SOUTH AFRICA

AUSTRIA

GERMANY

BELGIUM

HOLLAND

SWITZERLAND

DENMARK

FINLAND

IRELAND

Model

Code

5

5HNG 010 CANADA

Production

Code No.

090 GREECE

100 PORTUGAL

110 SWEDEN

Country

(destination)

(5) Coloring Information

Model

Code

5HNE

5HNF

5HNG

A6

NORWAY

070 SPAIN

Colouring type

code

A 0583

Colour

code

Colour Name

DEEP PURPLISH BLUE

SOLID E

Abbrevi-

ation

DPBSE

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.
NO.

10 90201−08609 WASHER, PLATE 4 4 4

11 90176−08026 NUT, CROWN 4 4 4

12 94701−00372 PLUG SPARK (NGK CR6HSA) 1 1 1 UR

13 4GL−11181−00 GASKET, CYLINDER HEAD 1 1 1 1

14 99530−10114 PIN, DOWEL 2 2 2

PART NO. DESCRIPTION REMARKS

1 4GL−11110−11 CYLINDER HEAD ASSY 1 1 1

2 4GL−11134−10 .GUIDE, EXHAUST VALVE 2 2 2

3 93210−09418 .O−RING 2 2 2

4 22F−14651−00 .BOLT, STUD 2 2 2

5 50M−11185−01 COVER, CYLINDER HEAD SIDE 1 1 1 1

6 93210−63556 O−RING 1 1 1

7 98507−06016 SCREW, PAN HEAD 2 2 2

8 22F−11186−00 COVER, CYLINDER HEAD SIDE 2 2 2 2

9 93210−44704 O−RING 2 2 2

94701−00283 PLUG, SPARK (ND U20FSR−U) 1 1 1 UR

5HNE

5HNF

5HNG

B2

15 95027−06085 BOLT, FLANGE 1 1 1

16 90105−06004 BOLT, FLANGE 1 1 1

17 4GL−11311−01 CYLINDER 1 1 1 1

18 5HN−11351−00 GASKET, CYLINDER 1 1 1

19 90465−08230 CLAMP 1 1 1

FIG. 2 CRANKSHAFT. PISTON

REF.
NO.

10 4GL−11445−00 SPACER 1 1 1

11 4GL−11631−01 PISTON (STD) 1 1 1

12 22K−11633−01 PIN, PISTON 1 1 1

13 93450−14088 CIRCLIP 2 2 2

PART NO. DESCRIPTION REMARKS

1 5HN−11400−01 CRANKSHAFT ASSY 1 1 1

2 5HN−W1141−00 .CRANK 1 1 1 1

3 4GL−11681−10 .PIN, CRANK 1 1 1 1

4 93310−326M9 .BEARING 1 1 1

5 4GL−11651−01 .ROD, CONNECTING 1 1 1

6 5HN−11422−00 .CRANK 2 1 1 1

7 5DV−11445−00 .SPACER 1 1 1

8 93306−20590 .BEARING 1 1 1

9 90280−03017 KEY, WOODRUFF 1 1 1

4GL−11636−01 PISTON (0.50MM O/S) 1 1 1 AP

4GL−11638−01 PISTON (1.00MM O/S) 1 1 1 AP

5HNE

5HNF

5HNG

B3

14 22K−11610−01 PISTON RING SET (STD) 1 1 1

22K−11610−21 PISTON RING SET (0.50MM O/S) 1 1 1 AP

22K−11610−41 PISTON RING SET (1.00MM O/S) 1 1 1 AP

FIG. 3 VALVE

REF.
NO.

10 22F−12156−00 SHAFT, ROCKER 2 2 2 2

PART NO. DESCRIPTION REMARKS

1 4GL−12111−11 VALVE, INTAKE 1 1 1

2 4GL−12121−01 VALVE, EXHAUST 1 1 1

3 1WG−12119−00 SEAL, VALVE STEM 2 2 2

4 5DV−12114−01 SPRING, VALVE OUTER 2 2 2

5 1WG−12118−00 COTTER, VALVE 4 4 4

6 3UH−12117−00 RETAINER, VALVE SPRING 2 2 2

7 22F−12151−00 ARM, VALVE ROCKER 2 2 2

8 22F−12159−00 SCREW, VALVE ADJUSTING 2 2 2

9 90170−05302 NUT 2 2 2

5HNE

5HNF

5HNG

B4

FIG. 4 CAMSHAFT. CHAIN

REF.
NO.

10 90110−06091 BOLT, HEXAGON SOCKET HEAD 2 2 2

11 4GL−12210−00 TENSIONER ASSY, CAM CHAIN 1 1 1

12 4RF−12213−00 GASKET, TENSIONER CASE 1 1 1

13 90430−06014 GASKET 2 2 2

14 91317−06016 BOLT 2 2 2

PART NO. DESCRIPTION REMARKS

1 5HN−12170−00 CAMSHAFT ASSY 1 1 1 1

2 4GL−1111F−00 PLATE 1 1 1

3 90110−06226 BOLT, HEXAGON SOCKET HEAD 1 1 1

4 4GL−12176−00 SPROCKET, CAM CHAIN 1 1 1

5 90201−08326 WASHER, PLATE 1 1 1

6 90101−08590 BOLT 1 1 1

7 94591−51084 CHAIN 1 1 1

8 4GL−12231−00 GUIDE, STOPPER 1 1 1 1

9 4GL−12241−00 GUIDE, STOPPER 2 1 1 1

5HNE

5HNF

5HNG

B5

FIG. 5 OIL PUMP

REF.
NO.

10 4GL−13324−00 GEAR, PUMP DRIVE 1 1 1

11 4GL−13451−01 FILTER,ROTARY 1 1 1

PART NO. DESCRIPTION REMARKS

1 4GL−13300−01 OIL PUMP ASSY 1 1 1

2 4GL−13325−00 .GEAR, PUMP DRIVEN (34T) 1 1 1

3 99001−05600 .CIRCLIP 1 1 1

4 90208−07052 .WASHER, CONICAL SPRING 1 1 1

5 22F−13329−01 GASKET, PUMP COVER 1 1 1

6 90155−06007 SCREW, FLAT FILLISTER 2 2 2

7 90340−12001 PLUG, STRAIGHT SCREW 1 1 1

8 812−11198−00 GASKET 1 1 1

9 22F−13411−01 STRAINER, OIL 1 1 1

5HNE

5HNF

5HNG

B6

FIG. 6 INTAKE

REF.
NO.

10 5HN−14437−00 DUCT 1 1 1

11 5HN−14453−00 JOINT, AIR CLEANER 1 1 1 1

12 12R−14452−00 SEAL 1 1 1

13 59V−14457−00 SEAL 1 1 1

14 90467−22080 CLIP 1 1 1

15 98507−06025 SCREW, PAN HEAD 3 3 3

PART NO. DESCRIPTION REMARKS

1 5HN−13586−10 JOINT, CARBURETOR 1 1 1 1

2 4GL−13595−00 JOINT 1 1 1

3 93210−25552 O−RING 2 2 2

4 91317−06035 BOLT 2 2 2

5 91317−06025 BOLT 2 2 2

6 5HN−14411−00 CASE, AIR CLEANER 1 1 1 1

7 5HN−14412−00 CAP, CLEANER CASE 1 1 1 1

8 5HN−14472−00 PLATE, ELEMENT 1 1 1

9 5HN−14451−00 ELEMENT, AIR CLEANER 1 1 1

5HNE

5HNF

5HNG

B7

16 92907−06600 WASHER, PLATE 3 3 3

17 90159−06056 SCREW, WITH WASHER 2 2 2

18 5TN−E3575−00 BAND 1 1 1

FIG. 7 CARBURETOR

REF.
NO.

10 12R−14191−00 .PLUG, DRAIN 1 1 1

11 98507−04014 .SCREW, PAN HEAD 4 4 4

12 92907−04100 .WASHER, SPRING 4 4 4

13 4GL−14103−00 .THROTTLE SCREW SET 1 1 1

14 5HN−14985−00 .FLOAT 1 1 1

15 4GL−1410A−00 .STARTER SET 1 1 1

PART NO. DESCRIPTION REMARKS

1 5HN−14101−01 CARBURETOR ASSY 1 1 1 1

2 4GL−14239−00 .SEAL 1 1 1

3 18A−14143−18 .JET, MAIN (# 90) 1 1 1

4 5HN−14141−13 .NOZZLE, MAIN 1 1 1

5 5HN−1490J−00 .NEEDLE SET 1 1 1

6 3KD−14142−12 .JET, PILOT (# 12.5) 1 1 1

7 7LG−14150−11 .NEEDLE ASSY 1 1 1

8 353−14186−00 .PIN, FLOAT 1 1 1

9 4GL−14104−00 .AIR SCREW SET 1 1 1

5HNE

5HNF

5HNG

B8

16 5HN−14135−00 ..SPRING, PLUNGER 1 1 1

17 5HN−14112−25 .VALVE, THROTTLE 1 1 1 1

18 241−14147−00 .O−RING 1 1 1

19 4GL−14348−00 .PIPE 1 1 1 1

20 5HN−14987−00 .HOSE 1 1 1

21 98507−04012 .SCREW, PAN HEAD 2 2 2

22 92907−04100 .WASHER, SPRING 2 2 2

23 4NM−14275−00 .SPRING 1 1 1

24 4NM−14198−00 .GASKET 1 1 1

25 5HN−14148−00 .PIPE 1 1 1

26 522−14161−00 .NUT, CABLE ADJUSTING 1 1 1