YAMAHA TTR90ES PARTS CATALOGUE 04-1

TTR90ES (5HNL) U.S.A. TTR90E (5HNM) EUROPE,S.AFRICA TTR90ES (5HNM) OCEANIA TTR90ES (5HNN) CANADA

1C5HN-100EB

2C5HN-100EB

()

TTR90ES/TTR90E

PARTS CATALOGUE

1st edition, July 2003

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan.

FOREWORD

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

1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the 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” Locally Made (Parts need to be ordered locally) “F#” Frame No. (Applicable machine No.) “O/S” Over Size

3. The number of components for assembly

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

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

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

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

4. Applicable colours of graphics are represented in the “REMARKS” as shown below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4–24110–00–X5 FUEL TANK COMP. 2 MXR

3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR

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

7. Applicable Serial No.

Engine Serial No. Frame Serial No.

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation Colour Name Colour Code

DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583

SL SILVER 0035

FOREWORD

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–reference the “model code – production code No.” in the catalogue with the “model code – production code No.” indicated on the Model Label affixed onto the product concerned.

(2) “Model Label” Indication

(3) Model Label Affixing Location

(4) Colouring Information

Model Code

5HNL

5HNM

5HNN

Colouring

Type Code

A 0583

Colour

Code

Colour Name

DEEP PURPLISH BLUE SOLID E DPBSE

Abbrevia-

tion

(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue

Model

Code

5HNL 010 U.S.A.

5HNM

5HNN 010 CANADA

Production

Code No.

010 FRANCE

020

030

040

050 SWITZERLAND

060

070 SPAIN

080

090 GREECE

100 PORTUGAL

110 SWEDEN

Country

(destination)

AUSTRALIA

NEW ZEALAND

SOUTH AFRICA

AUSTRI A

GERMANY

BELGIUM

HOLLAND

DENMARK

FINLAND

IRELAND

NORWAY

UNITED KINGDOM

Model

Code

Production

Code No.

Country

(destination)

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

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

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

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

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

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

INDEX

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

CONTENTS

FIG. 1 CYLINDER HEAD

REF. NO.

PART NO. DESCRIPTION

4GL–11110–11

4GL–11134–10

93210–09418

22F–14651–00

50M–11185–01

93210–63556

98507–06016

22F–11186–00

93210–44704

90201–08609

90176–08026

94701–00372

CYLINDER HEAD ASSY 1 1 1

.GUIDE, VALVE 2 2 2 2

.O-RING 2 2 2

.BOLT, STUD 2 2 2

COVER, CYLINDER HEAD SIDE 1 1 1 1

O-RING 1 1 1

SCREW, PAN HEAD 2 2 2

COVER, CYLINDER HEAD SIDE 2 2 2 2

O-RING 2 2 2

WASHER, PLATE 4 4 4

NUT, CROWN 4 4 4

PLUG SPARK (NGK CR6HSA) 1 1 1 UR

5HNL

5HNM

5HNN

REMARKS

94701–00283

4GL–11181–00

99530–10114

95027–06085

90105–06004

4GL–11311–01

5HN–11351–00

90465–08230

PLUG, SPARK (ND U20FSR-U) 1 1 1 UR

GASKET, CYLINDER HEAD 1 1 1 1

PIN, DOWEL 2 2 2

BOLT, FLANGE 1 1 1

CYLINDER 1 1 1 1

GASKET, CYLINDER 1 1 1

CLAMP 1 1 1

FIG. 2 CRANKSHAFT & PISTON

REF. NO.

PART NO. DESCRIPTION

5HN–11400–01

5HN–W1141–00

4GL–11681–10

93310–326M9

4GL–11651–01

5HN–11422–00

5DV–11445–00

93306–20590

90280–03017

4GL–11445–00

4GL–11631–01

CRANKSHAFT ASSY 1 1 1

.CRANK 1 1 1 1

.PIN, CRANK 1 1 1 1

.BEARING 1 1 1

.ROD, CONNECTING 1 1 1

.CRANK 2 1 1 1

.SPACER 1 1 1

.BEARING 1 1 1

KEY, WOODRUFF 1 1 1

SPACER 1 1 1

PISTON (STD) 1 1 1

5HNL

5HNM

5HNN

REMARKS

4GL–11636–01

4GL–11638–01

22K–11633–01

93450–14088

22K–11610–01

22K–11610–21

22K–11610–41

PISTON (0.50MM O/S) 1 1 1 AP

PISTON (1.00MM O/S) 1 1 1 AP

PIN, PISTON 1 1 1

CIRCLIP 2 2 2

PISTON RING SET (STD) 1 1 1

PISTON RING SET (0.50MM O/S) 1 1 1 AP

PISTON RING SET (1.00MM O/S) 1 1 1 AP

FIG. 3 VALVE

REF. NO.

PART NO. DESCRIPTION

4GL–12111–11

4GL–12121–01

1WG–12119–00

5DV–12114–01

1WG–12118–00

3UH–12117–00

22F–12151–00

22F–12159–00

90170–05302

22F–12156–00

VALVE, INTAKE 1 1 1

VALVE, EXHAUST 1 1 1

SEAL, VALVE STEM 2 2 2

SPRING, VALVE OUTER 2 2 2

COTTER, VALVE 4 4 4

RETAINER, VALVE SPRING 2 2 2

ARM, VALVE ROCKER 2 2 2

SCREW, VALVE ADJUSTING 2 2 2

NUT 2 2 2

SHAFT, ROCKER 2 2 2 2

5HNL

5HNM

5HNN

REMARKS

FIG. 4 CAMSHAFT & CHAIN

REF. NO.

PART NO. DESCRIPTION

5HN–12170–00

4GL–1111F–00

90110–06226

4GL–12176–00

90201–08326

90101–08590

94591–51084

4GL–12231–00

4GL–12241–00

90110–06091

4GL–12210–00

4RF–12213–00

90430–06014

91317–06016

CAMSHAFT ASSY 1 1 1 1

PLATE 1 1 1

BOLT, HEXAGON SOCKET HEAD 1 1 1

SPROCKET, CAM CHAIN 1 1 1

WASHER, PLATE 1 1 1

BOLT 1 1 1

CHAIN 1 1 1

GUIDE, STOPPER 1 1 1 1

GUIDE, STOPPER 2 1 1 1

BOLT, HEXAGON SOCKET HEAD 2 2 2

TENSIONER ASSY, CAM CHAIN 1 1 1

GASKET, TENSIONER CASE 1 1 1

GASKET 2 2 2

BOLT 2 2 2

5HNL

5HNM

5HNN

REMARKS

FIG. 5 OIL PUMP

REF. NO.

PART NO. DESCRIPTION

4GL–13300–01

4GL–13325–00

99001–05600

90208–07052

22F–13329–01

90155–06007

90340–12001

812–11198–00

22F–13411–01

4GL–13324–00

4GL–13451–01

OIL PUMP ASSY 1 1 1

.GEAR, PUMP DRIVEN (34T) 1 1 1

.CIRCLIP 1 1 1

.WASHER, CONICAL SPRING 1 1 1

GASKET, PUMP COVER 1 1 1

SCREW, FLAT FILLISTER 2 2 2

PLUG, STRAIGHT SCREW 1 1 1

GASKET 1 1 1

STRAINER, OIL 1 1 1

GEAR, PUMP DRIVE 1 1 1

FILTER,ROTARY 1 1 1

5HNL

5HNM

5HNN

REMARKS

FIG. 6 INTAKE

REF. NO.

PART NO. DESCRIPTION

5HN–13586–10

4GL–13595–00

93210–25552

91317–06035

91317–06025

5HN–14411–00

5HN–14412–00

5HN–14472–00

5HN–14451–00

5HN–14437–00

5HN–14453–00

12R–14452–00

59V–14457–00

90467–22080

98507–06025

JOINT, CARBURETOR 1 1 1 1

JOINT 1 1 1

O-RING 2 2 2

BOLT 2 2 2

CASE, AIR CLEANER 1 1 1 1

CAP, CLEANER CASE 1 1 1 1

PLATE, ELEMENT 1 1 1

ELEMENT, AIR CLEANER 1 1 1

DUCT 1 1 1

JOINT, AIR CLEANER 1 1 1 1

SEAL 1 1 1

CLIP 1 1 1

SCREW, PAN HEAD 3 3 3

5HNL

5HNM

5HNN

REMARKS

92907–06600

90159–06056

5TN–E3575–00

WASHER, PLATE 3 3 3

SCREW, WITH WASHER 2 2 2

BAND 1 1 1

FIG. 7 CARBURETOR

REF. NO.

PART NO. DESCRIPTION

5HN–14101–01

4GL–14239–00

18A–14143–18

5HN–14141–13

5HN–1490J–00

3KD–14142–12

7LG–14150–11

353–14186–00

4GL–14104–00

12R–14191–00

98507–04014

92907–04100

4GL–14103–00

5HN–14985–00

4GL–1410A–00

CARBURETOR ASSY 1 1 1 1

.SEAL 1 1 1

.JET, MAIN (# 90) 1 1 1

.NOZZLE, MAIN 1 1 1

.NEEDLE SET 1 1 1

.JET, PILOT (# 12.5) 1 1 1

.NEEDLE ASSY 1 1 1

.PIN, FLOAT 1 1 1

.AIR SCREW SET 1 1 1

.PLUG, DRAIN 1 1 1

.SCREW, PAN HEAD 4 4 4

.WASHER, SPRING 4 4 4

.THROTTLE SCREW SET 1 1 1

.FLOAT 1 1 1

.STARTER SET 1 1 1

5HNL

5HNM

5HNN

REMARKS

5HN–14135–00

5HN–14112–25

241–14147–00

4GL–14348–00

5HN–14987–00

98507–04012

92907–04100

4NM–14275–00

4NM–14198–00

5HN–14148–00

522–14161–00

..SPRING, PLUNGER 1 1 1

.VALVE, THROTTLE 1 1 1 1

.O-RING 1 1 1

.PIPE 1 1 1 1

.HOSE 1 1 1

.SCREW, PAN HEAD 2 2 2

.WASHER, SPRING 2 2 2

.SPRING 1 1 1

.GASKET 1 1 1

.PIPE 1 1 1

.NUT, CABLE ADJUSTING 1 1 1

+ 30 hidden pages

YAMAHA TTR90ES PARTS CATALOGUE 04-1

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

MODEL LABEL

ENGINE

CHASSIS