Yamaha TTR 90 2001 Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TTR90 Year: 2001 Product Type: Service Repair Manual 👋 Introduction Market Position Target Audience: Owners and mechanics of the 2001 Yamaha TTR90 off-road...

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Type: Motorcycle

Vendor:

Sku: 482524

Tags: 2001 Motorcycle Motorcycles TTR 90 TTR Models Yamaha

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TTR90

Year:

Product Type:

Service Repair Manual

👋 Introduction

Market Position

Target Audience:

Owners and mechanics of the 2001 Yamaha TTR90 off-road motorcycle.

Vehicle Category:

Entry-level to intermediate off-road/trail motorcycle.

Competitive Analysis

Competitors:

Honda XR70/80, Suzuki JR80, Kawasaki KX65/85 (though often positioned slightly differently).

Key Features

Vehicle Appeal:

User-friendly, reliable, and durable for young riders and trail riding.

Manual Value

Benefit:

Enables proper maintenance, repair, and troubleshooting to extend the life and performance of the motorcycle.

📋 Manual Details

Coverage Areas

Engine:

Comprehensive coverage of the TTR90 engine system.

Transmission:

Detailed information on the gearbox and clutch operation.

Chassis:

Suspension, frame, steering, and wheel components.

Electrical System:

Ignition, lighting, charging system, and wiring diagrams.

Brakes:

Front and rear brake system maintenance and repair.

Fuel System:

Carburetor adjustment, cleaning, and fuel delivery.

Troubleshooting:

Diagnostic procedures for common and uncommon issues.

Page Count

Estimated Pages:

Varies by specific edition, typically 150-300 pages for comprehensive coverage.

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Top-end overhaul, piston and cylinder replacement, valve clearance adjustment.

Engine Lubrication:

Oil change procedures, oil pump inspection, and oil filter replacement.

Cooling System:

N/A (Air-cooled engine)

Ignition System:

CDI unit testing, spark plug selection and gap, stator coil inspection.

Fuel And Carburetion:

Carburetor model identification, jetting specifications, idle speed adjustment, float height.

Transmission System:

Clutch adjustment, clutch plate replacement, gear shift mechanism repair.

Drivetrain:

Chain and sprocket maintenance, replacement, and adjustment.

Suspension Front:

Fork oil change, seal replacement, spring inspection.

Suspension Rear:

Shock absorber inspection and adjustment, linkage lubrication.

Steering System:

Headstock bearing adjustment and replacement.

Brake System Front:

Brake lever adjustment, pad replacement, caliper service.

Brake System Rear:

Brake pedal adjustment, drum brake service, shoe replacement.

Electrical Charging:

Stator output testing, rectifier/regulator function check.

Electrical Lighting:

Headlight, taillight, and brake light bulb replacement.

Electrical Wiring:

Complete color-coded wiring diagrams for troubleshooting.

Procedures Included

Preventative Maintenance:

Regular service checks, lubrication points, and component inspections.

Troubleshooting Guides:

Step-by-step diagnostic charts for common running issues.

Engine Overhaul:

Detailed instructions for complete engine disassembly and reassembly.

Carburetor Tuning:

Procedures for adjusting fuel mixture and idle speed.

Suspension Servicing:

Fork seal replacement and rear shock maintenance.

Brake Service:

Brake pad/shoe replacement and drum/caliper cleaning.

Electrical Diagnostics:

Testing components like CDI, ignition coil, and charging system.

Component Replacement:

Instructions for replacing commonly worn parts like chains, sprockets, cables.

Technical Depth

Depth:

Comprehensive, suitable for DIY mechanics and professional technicians.

Diagnostic Level:

Advanced diagnostic procedures using specified measurements and tolerances.

Rebuild Level:

Full engine and transmission rebuild procedures.

📊 Manual Specifications

File Format

Format:

Searchable:

Yes (typically text-searchable PDF)

Print Quality

Quality:

High-resolution, clear text and graphics.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Illustrations

Type:

Detailed diagrams, exploded views, and photographic steps.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 2-stroke, single-cylinder

Displacement:

89 cc

Bore X Stroke:

47.0 mm x 50.0 mm (typical for this era TTR90)

Compression Ratio:

6.0:1 (typical, subject to manual confirmation)

Performance

Horsepower:

Approx. 6-8 HP @ 7000-8000 RPM (estimated, manual will provide exact)

Torque:

Approx. 5-6 lb-ft @ 6000-7000 RPM (estimated, manual will provide exact)

Fuel System

Carburetor:

Mikuni VM17 (typical, manual will confirm specific variant)

Fuel Type:

Unleaded gasoline

Fuel Mixture:

2-stroke oil mixed with gasoline

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Starting

Starter Type:

Kickstarter

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed sequential

Clutch Type:

Wet, multi-plate

Drive Type:

Chain drive

Features

Gear Ratios:

Specifications will be detailed in the manual.

Clutch Adjustment:

Cable free play adjustment procedures included.

📐 Dimensions

Exterior

Overall Length:

Approx. 1740 mm (68.5 in)

Overall Width:

Approx. 720 mm (28.3 in)

Overall Height:

Approx. 1040 mm (40.9 in)

Wheelbase:

Approx. 1215 mm (47.8 in)

Ground Clearance:

Approx. 260 mm (10.2 in)

Seat Height:

Approx. 750 mm (29.5 in)

Weights

Dry Weight:

Approx. 75 kg (165 lbs)

Fuel Tank Capacity:

Approx. 4.1 L (1.1 gal)

Dimensions

Front Tire Size:

2.50-12 4PR

Rear Tire Size:

3.00-10 4PR

Front Suspension Travel:

140 mm (5.5 in)

Rear Suspension Travel:

150 mm (5.9 in)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Off-road motorcycles are not typically rated by consumer safety organizations like NHTSA or IIHS).

Active Features

Braking System:

Drum brakes front and rear (typical for model year).

Passive Features

Frame Construction:

Steel semi-double cradle frame for stability and durability.

💡 Technology Features

Infotainment

Features:

N/A (Basic off-road motorcycle with no infotainment systems).

Driver Assistance

Features:

N/A (No electronic driver assistance features).

Connectivity

Features:

N/A (No connectivity features).

🔧 Maintenance

Service Intervals

Oil Change:

Every 1000 km or 6 months (refer to manual for precise Yamaha recommendations).

Air Filter Cleaning:

Clean every 500 km or as needed based on riding conditions.

Spark Plug Inspection:

Inspect every 1000 km, replace as needed.

Chain Lubrication:

Lubricate chain every 500 km or after riding in wet conditions.

Valve Clearance:

Check and adjust every 2000 km (or as per manual's recommendation for 2-strokes, often less frequent than 4-strokes).

Fluid Specifications

Engine Oil Type:

Yamalube 2-stroke oil or equivalent API-TC or JASO FD certified oil.

Transmission Oil Type:

Yamalube Gear Oil (or equivalent SAE 10W-30 API SE or higher).

Fork Oil Type:

Yamaha Suspension Oil (or equivalent SAE 10W) - Capacity specified in manual.

Known Issues

Common Wear Items:

Clutch plates, brake shoes/pads, chain and sprockets, fork seals, carburetor jets.

Carburetor Fouling:

Can be prone to fouling if not used regularly or if fuel quality is poor.

Throttle Cable Wear:

Throttle cable can wear and require adjustment or replacement over time.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company, a globally recognized leader in motorcycles, marine products, and other motorized vehicles.

Model Evolution

Ttr Series Context:

The TTR series is Yamaha's line of trail-oriented off-road motorcycles, known for their usability and reliability, bridging the gap between beginner play bikes and full-sized dirt bikes.

Ttr90 Placement:

The TTR90 was designed as an accessible entry-point into off-road riding for younger or less experienced riders.

Production

Production Years:

The TTR90 was produced for several years, with the 2001 model being a representative example of its generation.

Manufacturing Location:

Likely manufactured in Japan or Southeast Asia by Yamaha.

🏆 Awards & Recognition

Recognitions

Awards:

N/A (No specific industry awards typically given to individual model years of this type of vehicle).