Target Audience:
Owners and independent repair shops servicing the Yamaha TTR90 off-road motorcycle, particularly those from the mid-2000s era. Essential for maintaining performance, reliability, and longevity.
Manual Value Proposition:
Provides in-depth technical knowledge typically reserved for authorized Yamaha service centers. Crucial for accurate diagnostics and repairs, saving significant costs compared to dealership service. Superior to generic online guides or owner's manuals for repair tasks.
Manual Benefits:
Empowers owners to perform complex maintenance and repairs. Detailed troubleshooting sections aid in diagnosing and resolving issues efficiently. Includes all specifications necessary for proper servicing.
Primary Coverage:
Complete Service and Repair
Estimated Page Count:
Highly variable, typically 300-600 pages for full workshop manuals of this era and type. Specific count not provided, but described as 'COMPLETE'.
Manual Type:
Workshop Manual / Service Manual / Repair Manual
Language:
English (Assumed based on standard industry practice for global markets)
Format:
Digital (Likely PDF, as indicated by typical online sales for this product type, though not explicitly stated. Could also be printable physical copy).
Engine Systems:
Engine overhaul, top-end (cylinder head, valves, piston), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable), fuel system (carburetor tuning, jetting), ignition system (CDI, spark plug), starting system (kick starter mechanism).
Drivetrain Systems:
Clutch operation and adjustment, transmission disassembly/assembly, gear inspection, final drive (chain and sprockets).
Chassis Systems:
Frame inspection and repair, suspension (front fork disassembly, rear shock absorber, linkage), steering system (handlebars, steering stem bearings), wheel and tire service, brake system (front and rear drum/disc, hydraulic components, bleeding), electrical system (wiring diagrams, lighting, switches, battery).
Bodywork And Trim:
Body panel removal and installation, seat, fenders, tank.
Maintenance Procedures:
Routine checks, lubrication points, chain adjustment, brake adjustment, tire pressure, air filter cleaning/replacement, spark plug replacement, oil changes.
Repair Procedures:
Engine rebuild, transmission repair, suspension servicing, brake caliper overhaul, carburetor rebuilding, electrical component replacement.
Troubleshooting Guidance:
Diagnostic charts for common running issues (e.g., hard starting, poor performance, misfires), electrical troubleshooting flowcharts.
Technical Data And Specs:
Torque specifications for all fasteners, engine timing procedures, valve clearance adjustments, diagnostic trouble codes (if applicable), fluid capacities, recommended oil types and viscosities.
Depth Of Coverage:
Comprehensive. Covers from basic preventative maintenance to complete engine and chassis teardown and rebuild. Includes detailed diagrams, exploded views, and step-by-step instructions suitable for skilled DIY mechanics and professional technicians.
Digital Format Details:
Likely PDF. Searchable text functionality is common for well-produced digital manuals, allowing quick access to information via keywords. Print-friendly pages are a standard expectation.
Print Quality Expectation:
High-quality reproductions of original factory manuals. Clear line drawings, schematics, and photographic references (if included in original).
Physical Binding:
If physical: Spiral-bound or perfect-bound for durability and ease of use (lying flat on a workbench). If digital: N/A.
Physical Paper Type:
If physical: Durable, possibly coated paper to resist grease and shop contaminants. If digital: N/A.
Engine Type:
Air-cooled, 4-stroke, SOHC
Displacement:
88cc (Actual displacement may vary slightly by exact sub-model or region, but commonly cited)
Bore X Stroke:
Typically 48.0 x 49.7 mm
Compression Ratio:
Approximately 9.7:1
Carburetor Type:
Mikuni VM17 (Commonly fitted)
Horsepower:
Estimated 6-7 HP (Highly dependent on specific model year and tuning; exact figures often not published for entry-level models)
Torque:
Estimated 5-6 Nm (Similar caveat as horsepower)
Fuel Delivery:
Carburetor
Fuel Type:
Unleaded Gasoline (90+ Octane Recommended)
Safety Ratings Context:
Off-road motorcycles are not typically subjected to formal crash safety ratings like passenger vehicles. Safety emphasis is on rider protection and vehicle handling.
Braking System:
Front and rear drum brakes are standard on many TTR90 models. Some later or special editions might feature a front disc brake. Manual will detail specific configuration.
Suspension System:
Front telescopic forks and rear swingarm with monoshock provide stability and impact absorption. Manual details adjustment and maintenance.
Frame Construction:
Steel frame provides structural integrity for off-road use.
Tire Specification:
Off-road knobby tires for grip. Manual will specify recommended sizes and pressures.
Oil Change Interval:
Typically every 1,000-2,000 km or 6-12 months, whichever comes first. Specific interval detailed in manual. Off-road use may necessitate more frequent changes.
Air Filter Service:
Check and clean every 500 km or as needed based on dust conditions. Replacement is also covered.
Spark Plug Replacement:
Typically recommended every 3,000-5,000 km or annually.
Chain Lubrication Adjustment:
Lubricate every 300-500 km. Check tension at every ride and adjust as per manual's specification (typically 10-20mm free play).
Engine Oil Type:
Yamalube (or equivalent) 4-stroke motorcycle oil, SAE 10W-40 viscosity is common. Manual will specify exact grade and API classification.
Engine Oil Capacity:
Approximately 0.9 - 1.0 Liters (with filter change). Precise amount stated in the manual.
Transmission Oil Type:
Often shares engine oil. Manual will confirm.
Brake Fluid Type:
DOT 3 or DOT 4 for hydraulic front brakes (if equipped). Manual will specify.
Common Wear Items:
Brake shoes/pads (due to drum brakes), clutch friction plates (normal wear), tires, chain and sprockets, wheel bearings, suspension seals (forks). Manual provides procedures for inspection and replacement.
Carburetor Issues:
Clogging due to infrequent use or poor fuel quality. Manual provides cleaning and adjustment procedures.
Electrical Gremlins:
Loose connections, corroded terminals, or failing switches can occur over time, especially with off-road exposure. Detailed wiring diagrams in manual are essential for diagnosis.
Yamaha Offroad Legacy:
Yamaha has a long-standing reputation for producing reliable and capable off-road motorcycles, from small-displacement playbikes to professional motocross and enduro machines. The TTR series is a direct continuation of this heritage, offering accessible off-road performance for younger riders and beginners.
Ttr90 Lineage:
The TTR90 was designed as an entry-level, user-friendly off-road machine for youth riders, often serving as a step up from minibikes or smaller trail bikes. It emphasizes ease of use with its automatic transmission and manageable power delivery.
Production Period:
The TTR90 was produced for a significant period, with the 2006 model being representative of its later iterations. Models existed from the late 1990s/early 2000s through to the mid-to-late 2000s, with updates to styling and minor component changes.
Manufacturing Location:
Yamaha motorcycles are typically manufactured in Japan or at various international facilities, including Southeast Asia (e.g., Indonesia, Thailand).
