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2004 Yamaha TT-R90 TT-R90E TTR-90 TTR90E Service Repair Manual Motorcycle Detailed and Specific

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🏷️ Basic Information Identification Make: Yamaha Model: TT-R90 / TT-R90E Year: 2004 Market: Off-Road Motorcycle Codes Model Code Ttr90: TTR90 Model Code Ttr90E: TTR90E 👋 Introduction Market Position Segment: Entry-level...
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Type: Motorcycle
Vendor:
Sku: 355234
2004 Yamaha TT-R90 TT-R90E TTR-90 TTR90E Service Repair Manual Motorcycle Detailed and Specific
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TT-R90 / TT-R90E
Year:
2004
Market:
Off-Road Motorcycle
Codes
Model Code Ttr90:
TTR90
Model Code Ttr90E:
TTR90E
👋 Introduction
Market Position
Segment:
Entry-level off-road/mini-motocross motorcycle.
Target Demographic:
Young riders, beginners, recreational trail riders.
Competitive Analysis
Competitors:
Honda CRF50F, Kawasaki KLX110, Suzuki JR80.
Key Features Vehicle
Ease Of Use:
Designed for ease of riding and maintenance for young riders.
Durability:
Robust construction for off-road conditions.
Key Features Manual
Practicality:
Tailored for the off-road rider, focusing on practical repair and maintenance.
Clarity:
Detailed explanations and clear diagrams enhance understanding.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Page Count
Estimated Pages:
300+
Manual Type
Type:
Service Manual / Repair Manual / Workshop Guide
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of all engine components.
Engine Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel lines, fuel tank, and petcock.
Engine Ignition System:
CDI unit, ignition coil, spark plug, stator, and wiring.
Transmission:
Clutch operation, maintenance, and adjustment; gearbox disassembly and inspection.
Drivetrain:
Chain and sprockets inspection, adjustment, and replacement.
Suspension:
Front fork disassembly, service, and oil change; rear shock absorber inspection and adjustment.
Brakes:
Front and rear brake systems, including drum brake adjustment and inspection.
Electrical System:
Wiring diagrams, lighting, switches, battery maintenance, and troubleshooting.
Chassis Frame:
Frame inspection, steering head bearing service.
Bodywork Trim:
Removal and installation of fenders, seat, fuel tank cover, and other body panels.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication, air filter cleaning, spark plug replacement.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon issues.
Rebuild Procedures:
Detailed instructions for engine, carburetor, and suspension rebuilds.
Adjustment Procedures:
Clutch, throttle, and brake lever adjustments.
Torque Specifications:
Precise torque values for all critical fasteners.
Wiring Diagrams:
Comprehensive electrical system schematics.
Technical Depth
Depth Level:
Comprehensive: Covers basic to advanced repair and overhaul.
Target Audience:
Professional mechanics and knowledgeable DIY owners.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text content.
Print Quality
Resolution:
High-resolution, clear images and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
88 cc
Bore X Stroke:
47 x 51.1 mm
Compression Ratio:
9.5:1
Valve Configuration:
SOHC (Single Overhead Cam)
Performance
Horsepower:
Approx. 7-8 HP (estimated, unconfirmed by official spec sheet)
Torque:
N/A (specification not readily available)
Fuel System
Carburetor Type:
Mikuni VM17
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
1.1 L (0.29 US gal)
🔧 Transmission
Standard
Transmission Type:
Automatic
Gear Selection:
Forward 3-speed with automatic clutch
Clutch Type:
Wet, multiple-disc, automatic
Final Drive:
Chain drive
Features
Ease Of Operation:
Automatic clutch system simplifies shifting for beginners.
📐 Dimensions
Exterior
Overall Length:
1560 mm (61.4 in)
Overall Width:
720 mm (28.3 in)
Overall Height:
945 mm (37.2 in)
Seat Height:
685 mm (27.0 in)
Wheelbase:
1090 mm (42.9 in)
Ground Clearance:
135 mm (5.3 in)
Weights
Dry Weight:
72 kg (159 lbs)
Wet Weight:
N/A (specification not readily available)
Max Load Capacity:
N/A (specification not readily available)
🛡️ Safety Features
Ratings
Crash Safety Ratings:
N/A (Motorcycle, not subject to automotive crash ratings)
Active Features
Braking System:
Front drum brake, Rear drum brake. Designed for controlled stopping.
Suspension Stability:
Provides stable handling for off-road conditions.
Passive Features
Frame Construction:
Sturdy frame designed to withstand off-road impacts.
Safety Equipment:
Recommended safety gear (helmet, gloves, boots, etc.) is crucial for operation.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic off-road motorcycle, no electronic infotainment features).
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 1000 km or 6 months (refer to manual for exact details).
Air Filter Cleaning Interval:
Every 1000 km or 6 months, more frequently in dusty conditions.
Spark Plug Replacement Interval:
Refer to manual, typically around 5000 km or as needed based on condition.
Chain Lubrication Adjustment:
Every 500 km, more frequently under wet or dirty conditions.
Fluid Specifications
Engine Oil Type:
Yamaha Yamalube 4 (or equivalent SAE 10W-40 API SE, SF, SG, SH, SJ type).
Engine Oil Capacity:
0.80 L (0.85 US qt) without filter change; 0.90 L (0.95 US qt) with filter change.
Transmission Oil Type:
Uses engine oil (shared lubrication system).
Known Issues
Carburetor Issues:
Can be prone to clogging from debris or stale fuel; requires regular cleaning.
Clutch Wear:
Automatic clutch can wear over time with aggressive riding, leading to slippage.
Suspension Wear:
Front fork seals can leak, and rear shock absorber may lose damping effectiveness with heavy use.
Electrical Connections:
Corrosion on electrical connectors, especially in humid environments, can cause intermittent faults.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Company, Ltd.
Brand Focus:
Renowned for high-performance motorcycles, sporting goods, and marine products.
Model Evolution
Tt-R Series Introduction:
The TT-R line is Yamaha's series of beginner-friendly, off-road-oriented motorcycles.
Tt-R90 Introduction Year:
Introduced in the early 2000s as a successor to earlier models.
Tt-R90E Distinction:
The 'E' designation typically indicates electric start, offering greater convenience over kick-start only models.
Production
Production Period:
The TT-R90 was produced for a significant period, with the 2004 model representing a specific iteration.
Manufacturing Location:
Likely manufactured in Japan or by Yamaha's global manufacturing partners.
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (Specific awards not typically documented for this class of vehicle).
Ratings
Owner Satisfaction:
Generally well-regarded for its intended purpose as a reliable entry-level off-road bike.
Certifications
Emissions Certification:
Compliant with relevant emissions standards for its model year.
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