2007 Yamaha TT-R90(W) / TT-R90E(W) Service & Repair Manual (P/N 3P2-28197-E0)

This Yamaha service manual covers the 2007 TT-R90(W) and TT-R90E(W), including their kick-start and electric-start configurations. Publication 3P2-28197-E0, first edition May 2006, documents maintenance, mechanical repair, and electrical diagnosis.

• Engine repair: Cylinder-head and valve service, camshaft and timing-chain work, cylinder and piston inspection, crankcase separation, and crankshaft checks.

• Clutch and transmission: Wet multiple-disc and automatic centrifugal clutch inspection, kickstarter service, gearshaft disassembly, and shift-drum and shift-fork checks.

• Fuel system: VM16SH carburetor removal, disassembly, inspection, reassembly, float-height measurement, fuel-level adjustment, and fuel-cock testing.

• Chassis service: Drum-brake inspection, wheel-bearing replacement, telescopic fork rebuilding, steering-head service, swingarm checks, and drive-chain replacement.

• TT-R90E starting system: Starter-motor overhaul, starter-clutch inspection, battery service, charging-system diagnosis, and starting circuit cut-off system operation.

• Ignition and carburetor heating: Circuit diagrams, troubleshooting charts, coil tests, switch checks, and thermo-switch and carburetor-warmer testing.

• Maintenance and reference data: Periodic service charts, tightening torque tables, lubrication diagrams, model-specific cable routing, exploded views, and component wear limits.

Written primarily for Yamaha dealers and their qualified mechanics, this manual assumes a working knowledge of mechanical service and repair.

Engine, Clutch and Transmission Repair

The engine chapters go beyond external adjustments into valve-guide replacement, valve-seat inspection and lapping, piston-ring measurement, and internal engine inspection. Trochoid oil-pump coverage includes rotor-clearance checks, oil-strainer inspection, and rotary-filter service.

Clutch inspection distinguishes friction-plate wear from pitted clutch-housing dogs or clutch-boss splines that can cause erratic operation. Separate checks address the primary clutch housing, clutch shoes, primary clutch boss, and one-way engagement.

Transmission coverage includes main-axle and drive-axle disassembly, gear engagement, shaft runout, and shift-fork movement. Cylinder-head installation notes also flag possible damage and incorrect valve timing if the crankshaft is turned during camshaft installation.

Carburetor Inspection and Adjustment

The carburetor section covers jets, the needle valve, throttle valve, starter plunger, and float assembly. It distinguishes float-height measurement from fuel-level measurement with a gauge and provides separate adjustment information for Canadian and European/Oceanian configurations.

Fuel-system coverage also includes fuel-cock flow checks, intake-manifold inspection, and hose routing. Carburetor-warmer installation details accompany the mechanical carburetor procedures.

Forks, Steering and Drum Brakes

Front-fork procedures cover disassembly, damper-rod inspection, seal replacement, reassembly, oil quantity, and oil-level measurement. Steering-head inspection includes bearings and races; the manual warns that incorrect race installation can damage the steering-head pipe.

Front and rear drum-brake sections provide shoe-lining and drum inspection criteria, camshaft checks, and shoe-plate assembly details. Wheel and drive-chain sections address bearings, sprocket wear, chain measurement, and alignment.

Rear-shock coverage includes removal, installation, and spring-preload adjustment. The manual warns against opening the nitrogen-charged shock. Use appropriate protective equipment and securely support the machine before wheel or suspension work.

Electrical Fault Finding for Each Starting Configuration

Ignition troubleshooting addresses absent or intermittent spark through component checks and wiring inspection. Test specifications cover the ignition coil, pickup coil, source coil, lighting coil, and charging coil, with model-specific values where applicable.

For the TT-R90E, the neutral-switch and starting circuit cut-off relay logic helps distinguish an interlock problem from a defective starter motor during no-crank diagnosis. Starter-clutch coverage includes engagement checks and specified bolt replacement and staking.

Separate Ignition System and Carburetor Heating System circuit diagrams support the diagnostic charts. The latter includes thermo-switch continuity and carburetor-warmer resistance checks.

Maintenance Charts, Tools and Assembly References

Periodic maintenance covers valve clearance, oil changes, air-filter service, drive-chain adjustment, and braking assemblies. Canadian-model spark-arrester cleaning is identified separately.

The special-tool list includes the valve spring compressor (90890-04019) and flywheel puller (90890-01362), with regional tool-number alternatives. Lubrication System Diagrams, separate Cable Routing views for each model, and exploded assembly drawings support component identification and reassembly.

Examples of Valve-Clearance and Crankshaft Inspection Data

These examples show a small selection of the engine adjustment and inspection data in the manual.

Cold valve-clearance ranges are 0.05–0.09 mm for the intake and 0.08–0.12 mm for the exhaust, measured with the piston at top dead center on the compression stroke.

The crankshaft inspection specifies a runout limit of 0.030 mm, alongside connecting-rod clearance and crankshaft-width checks.

Searchable PDF and Enlargable Wiring Diagrams

Text search, bookmarks, and wiring detail: Searchable text and chapter/component bookmarks are available. The RETURN bookmark points to a separate file rather than a location within this PDF. Small wire-color and connector labels in the checked circuit diagrams are readable when enlarged.

Supplied as one printable, English-language 238-page PDF containing all eight chapters. The total includes the cover and introductory material, five blank pages, the manufacturer's back page, and two appended wiring-diagram sheets; these pages are already included in the stated total.