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Yamaha TTR 90 TT R90 Full Service & Repair Manual 2004-2006
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🏷️ Basic Information Identification Make: Yamaha Model: TTR90 Model Code: TT-R90 Product Type: Service and Repair Manual Codes Product Sku: YAM-TTR90-SRM-2004-2006 👋 Introduction Market Position Vehicle Segment: Youth/Beginner Off-Road Motorcycle...
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类型: Motorcycle
厂商:
斯库: 381060
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TTR90
Model Code:
TT-R90
Product Type:
Service and Repair Manual
Codes
Product Sku:
YAM-TTR90-SRM-2004-2006
👋 Introduction
Market Position
Vehicle Segment:
Youth/Beginner Off-Road Motorcycle
Target Audience:
Young riders, entry-level off-road enthusiasts
Competitive Analysis
Key Competitors:
Honda CRF70F, Suzuki JR80, Kawasaki KLX110 (different displacement but similar market)
Key Features
Manual Value Proposition:
Provides comprehensive factory-level repair and maintenance data for DIY mechanics and professionals.
Ease Of Use:
Digital format allows for easy searching, printing, and viewing on multiple devices.
📋 Manual Details
Coverage Areas
Applicable Years:
2004, 2005, 2006
Engine Variants Covered:
All TT-R90 models
Page Count
Estimated Pages:
300-500
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full overhaul, including cylinder head, piston, crankshaft, valve timing, lubrication system
Fuel System:
Carburetor tuning, cleaning, rebuilding; fuel lines, fuel tank maintenance
Ignition System:
CDI unit, ignition coil, spark plug specifications and testing
Cooling System:
Air-cooled system, heat dissipation, engine temperature monitoring
Exhaust System:
Muffler maintenance, exhaust pipe sealing, heat shields
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, final drive (chain and sprockets)
Chassis Frame:
Frame inspection, welds, engine mounting points
Suspension Front:
Fork inspection, oil replacement, seal replacement, damping adjustments
Suspension Rear:
Shock absorber inspection, spring preload adjustment, linkage lubrication
Brakes Front:
Drum brake inspection, shoe replacement, lever adjustment
Brakes Rear:
Drum brake inspection, shoe replacement, pedal adjustment
Wheels Tires:
Spoke tensioning, rim inspection, tire pressure, tire replacement
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (stator, rectifier)
Bodywork Plastics:
Fairing removal and installation, seat, fenders
Controls Cables:
Throttle cable adjustment, brake cable lubrication and adjustment, clutch cable adjustment
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain lubrication, spark plug checks, air filter cleaning
Troubleshooting Diagnostics:
Step-by-step fault finding for common and uncommon issues
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly
Carburetor Rebuild:
Detailed instructions for disassembling, cleaning, and reassembling the carburetor
Suspension Fork Rebuild:
Front fork oil change and seal replacement procedures
Brake Adjustment Service:
Front and rear brake adjustment and component replacement
Electrical Component Testing:
Testing of ignition system, lighting, and charging components
Wheel Truing Spoke Tensioning:
Instructions for maintaining wheel alignment and spoke tension
Technical Depth
Depth Of Coverage:
Comprehensive, from basic owner maintenance to complete engine and chassis rebuilds
Diagnostic Charts:
Detailed troubleshooting flowcharts for various symptoms
Torque Specifications:
Precise torque values for all critical fasteners
Clearances Tolerances:
Specifications for critical engine and chassis component clearances
Wiring Diagrams:
Detailed, clear electrical system wiring schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Printable:
Yes
Device Compatibility:
Computer, Tablet, Smartphone
Print Quality
Image Resolution:
High-resolution for clear diagrams and images
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
Licensing
Licensing Terms:
No expiry dates, perpetual access
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
88 cc (5.37 cubic inches)
Bore X Stroke:
47 x 51.1 mm (1.85 x 2.01 inches)
Compression Ratio:
9.5:1
Valve Clearance Intake:
0.04 - 0.09 mm (0.0016 - 0.0035 in)
Valve Clearance Exhaust:
0.04 - 0.09 mm (0.0016 - 0.0035 in)
Performance
Horsepower Est:
Approx. 7-8 HP (figures vary by source and tuning)
Torque Est:
Approx. 5-6 lb-ft (figures vary by source and tuning)
Fuel System
Carburetor Model:
Mikuni VM17
Fuel Capacity:
2.5 L (0.66 US gal)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Lubrication
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-30 API SG or higher)
Engine Oil Capacity:
0.90 L (0.95 US qt) without filter change, 1.00 L (1.06 US qt) with filter change
🔧 Transmission
Standard
Transmission Type:
Semi-automatic, 4-speed constant mesh
Clutch Type:
Wet, multiple-disc
Final Drive:
Chain drive (520 O-ring sealed)
Features
Shifting Mechanism:
Foot-operated shifter, no clutch lever required for upshifts.
Transmission Oil
Transmission Oil Type:
Yamalube Gear Oil (or equivalent SAE 80 API GL-4)
Transmission Oil Capacity:
0.55 L (0.58 US qt)
📐 Dimensions
Exterior
Overall Length:
1605 mm (63.2 in)
Overall Width:
710 mm (28.0 in)
Overall Height:
950 mm (37.4 in)
Seat Height:
685 mm (27.0 in)
Wheelbase:
1110 mm (43.7 in)
Ground Clearance:
215 mm (8.5 in)
Weights
Wet Weight Est:
73 kg (161 lbs)
Dry Weight Est:
68 kg (150 lbs)
Wheels Tires
Front Tire Size:
2.50-14 4PR
Rear Tire Size:
3.00-12 4PR
Front Wheel Type:
Spoked, 14-inch rim
Rear Wheel Type:
Spoked, 12-inch rim
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Off-road motorcycle, not subject to road safety ratings)
Active Features
Braking System:
Drum brakes front and rear for controlled stopping power.
Throttle Limiter:
Some models may have adjustable throttle stops for beginners.
Passive Features
Engine Guard:
Basic engine protection, manual covers inspection and replacement.
Handlebar Padding:
Features padded crossbar for rider safety.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic off-road motorcycle, no infotainment features)
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance systems)
Connectivity
Connectivity Features:
N/A (No connectivity features)
Engine Management
Ignition System Type:
Transistor Controlled Ignition (TCI) with CDI unit.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1000 km (600 mi) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1000 km (600 mi) or 6 months; replace if damaged.
Spark Plug Check:
Every 1000 km (600 mi) or 6 months.
Chain Lubrication Adjustment:
Every 500 km (300 mi) or after washing/riding in wet conditions.
Valve Clearance Check:
Every 4000 km (2500 mi) or 24 months.
Fluid Specifications
Engine Oil Spec:
SAE 10W-30 API SG or higher (e.g., Yamalube 4)
Transmission Oil Spec:
SAE 80 API GL-4 (e.g., Yamalube Gear Oil)
Known Issues
Common Wear Items:
Brake shoes, chain and sprockets, tires, fork seals, carburetor jets (clogging).
Carburetor Performance:
Can be prone to clogging due to fuel sitting if not maintained; jetting may require adjustment for altitude/climate.
Electrical Reliability:
While generally robust, wiring connections should be checked for corrosion, especially in wet environments.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha Corporation is a global leader in motorcycles, musical instruments, and other powered products, known for innovation and quality.
Model Evolution
Tt R Lineage:
The TT-R line represents Yamaha's commitment to accessible and reliable off-road recreational vehicles for younger riders.
Production
Production Period:
The TT-R90 was primarily produced from the early 2000s, with the 2004-2006 period being the focus of this manual.
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
N/A (Specific awards not typically documented for this utility-focused model; recognized for reliability in its class).