Yamaha TT-R 90(S) / TT-R 90E(S) 2000–2006 Repair Manual (P/N 5HN-28199-84-00)

• Exact model coverage: 2000 TT-R90(M), 2001 TT-R90(N), 2002 TT-R90(P), 2003 TT-R90(R) and TT-R90E(R), 2004 TT-R90(S)/TT-R90E(S), 2005 TT-R90(T)/TT-R90E(T), and 2006 TT-R90(V)/TT-R90E(V).
• Engine and transmission repair: Covers carburetor service, cylinder-head and valve-train work, piston and cylinder inspection, clutch repair, oil-pump service, crankcase separation, and internal transmission work.
• Chassis procedures: Includes wheel and drum-brake disassembly, wheel-bearing inspection, front-fork teardown and seal service, steering-bearing work, swingarm removal, rear-shock removal, and drive-chain adjustment.
• TT-R90E-specific systems: Separates the CDI magneto and starter-clutch work from the kick-start model and adds starter-motor, battery, fuse, relay, neutral-switch, and charging-system diagnosis.
• Diagnostic and visual support: Provides TT-R90 and TT-R90E wiring diagrams, cable-routing layouts, exploded job diagrams, and factory inspection charts for ignition, electric starting, charging, and carburetor heating faults.
• Factory reference content: Supplies component-specific torque tables, fluid and lubrication data, service limits, electrical test specifications, adjustment data, and Yamaha special-tool references.

These Yamaha Owner's Service Manuals cover the shared air-cooled, SOHC 89cc single-cylinder engine, wet-sump lubrication system, automatic clutch arrangement, and three-speed constant-mesh transmission. Each PDF contains English, French, and German text. The set combines rider operation, pre-operation checks, scheduled maintenance, and tuning with detailed disassembly, inspection, assembly, and repair information. Routine upkeep is owner-oriented, while internal engine, fork, and electrical repair is best suited to experienced mechanics who are comfortable with precision measurements, Yamaha special tools, and multimeter testing.

Eight Year-Specific Yamaha Publications

Coverage is year-specific rather than a blanket claim based on one book. Match the model-year suffix and code on the motorcycle to the corresponding manual:

The complete set contains 2,609 PDF pages. Regional machine codes are 5HN1/5HN2/5HN3/5HN4 (M), 5HN5/5HN6/5HN7 (N), 5HN8/5HN9/5HNA (P), 5HNB/5HNC/5HND (R), and 5HNE/5HNF/5HNG for E(R). The S/E(S) publication covers 5HNH/5HNJ/5HNK and 5HNL/5HNM/5HNN; T/E(T) covers 5HNR/5HNS and 5HNT/5HNU/5HNV; V/E(V) covers 5HNW/5HNX and 3P21/3P22/3P23. The four kick-start-only TT-R90 books for 2000-2003 do not contain TT-R90E starter and charging procedures; use the dedicated 2003 E(R) publication or one of the combined 2004, 2005, or 2006 books for electric-start repair.

Mechanical Repair and Inspection Depth

Exploded job diagrams introduce the major removal and disassembly sections, with accompanying charts for parts, quantities, lubrication points, replacement items, and related procedures. Top-end coverage includes the cylinder head, camshaft and rocker arms, valves and springs, valve-seat inspection, and cylinder, piston, ring, and pin measurements. Lower-engine work includes the wet multi-disc and centrifugal clutch assemblies, kick and shift shafts, oil pump and strainer, CDI rotor and stator, crankshaft and crankcase, shift forks, shift cam, and transmission shafts and gears.

The chassis chapters cover both wheel and drum-brake assemblies, brake shoes and cams, bearings, fork damper rods and oil seals, handlebar and control placement, steering races and bearings, and the swingarm/Monocross rear suspension. Inspection data covers runout, wear, free play, alignment, and adjustment. Rear-shock coverage includes removal, leakage inspection, and spring-preload adjustment rather than an internal damper rebuild.

Electrical diagnosis is organized around practical fault paths. The illustrated material includes the standard TT-R90 wiring diagram, the expanded TT-R90E wiring diagram, the no-spark inspection chart, the starter-motor inoperative chart, the charging-system chart, and the carburetor-heating inspection chart. Component checks cover ignition and pickup/source coils, switches, relays, starter-motor windings and brushes, the rectifier/regulator, battery and fuse, thermo switch, and carburetor heater.

The tool sections cross-reference market-specific Yamaha numbers. Examples include the 90890-03112 pocket tester, 90890-01362 flywheel puller, 90890-04086 clutch holding tool, and 90890-01184/90890-01186 fork-seal driver components. Repair cautions call for protecting the crankshaft end when using the flywheel puller and loading wheel bearings through the outer race only; ignoring either point can damage the crankshaft or bearing surfaces. Because these are youth off-road motorcycles, adult instruction and supervision are required, and the machine must be securely supported before wheel, fork, steering, or swingarm service.