2000–2002 Yamaha TT-R90 Owner’s Service Manual Set (P/N 5HN-28199-80)

Each volume can be used on its own. Match the model year and market code of your kick-start TT-R90 to the volume before using its specifications and special-tool references.

Searchable PDFs and Wiring Diagram

Text search and bookmarks: Searchable text in all three files. The embedded chapter bookmarks open the corresponding contents pages, where linked entries lead to individual sections. Small wire and connector labels are clear when zoomed in. The wiring diagram appears on the English page, with French and German legends on the facing page.

The ZIP contains three printable PDFs with English, French, and German text. The 863 pages include the original front and back covers and memo pages in each volume, plus one blank page each in the 2001 and 2002 files.

Engine, Chassis, and Electrical Service

This selection of workshop topics covers the main service and repair areas. The manuals also explain cold starting and engine break-in.

• Routine maintenance: Service intervals, lubrication points, spark plug inspection, brake and drive-chain adjustment, and spoke tightening.
• Carburetor service: Mikuni VM16SH removal, disassembly, jet, float, and needle-valve inspection, reassembly, and fuel-level adjustment.
• Engine repair: Cylinder head removal and cam timing, camshaft and rocker arm service, valve and spring inspection, and cylinder and piston checks.
• Clutch and transmission: Wet multi-disc and centrifugal primary clutch service, kick axle and shift shaft work, and transmission disassembly, inspection, and reassembly.
• Chassis service: Drum brakes, wheel bearings and runout, front fork oil seals and damper rods, handlebar and steering head service, and swingarm removal.
• Electrical diagnosis: Wiring and cable-routing diagrams, plus separate inspection charts for ignition faults and the carburetor heating circuit.

Yamaha prepared the step-by-step disassembly, repair, reassembly, and inspection procedures as a reference for mechanics.

Market Codes and Model Identification

The 2000 edition lists 5HN1 for the U.S. outside California, 5HN2 for California, 5HN3 for Europe and Oceania, and 5HN4 for Canada.

For 2001, 5HN5 is the U.S. code, 5HN6 covers Europe, Australia, and New Zealand, and 5HN7 is for Canada. For 2002, 5HN8 is the U.S. code, 5HN9 covers Europe, Australia, New Zealand, and South Africa, and 5HNA is for Canada. The later editions list one U.S. code each and identify the California models separately by name.

The identification pages show where to find the model label under the seat, the VIN on the right side of the steering head, and the engine serial number on the raised boss on the left side of the engine.

Engine Measurements and Internal Repairs

The top-end procedures cover valve guide and seat inspection, cylinder and piston measurements, and ring and piston-pin checks. Turning the crankshaft during camshaft installation can damage components or leave the valve timing incorrect.

The lower-end sections show how to inspect wet-sump oil pump rotor clearances, check crankshaft runout, and examine the shift forks, shift cam, main axle, and drive axle. The clutch procedures include plate warpage and centrifugal shoe wear checks. The oil notes specify which oils and additives to avoid because the engine oil also lubricates the clutch.

Rear Shock and Electrical Fault Isolation

Rear shock service is limited to removal, external inspection, and spring preload adjustment. Chassis removal charts show where the machine needs support on a stand. The fuel-handling notes warn about ignition sources and hot engine parts.

The ignition inspection chart helps trace a no-spark fault through wiring connections, the engine stop switch, ignition coil, and CDI magneto pickup and source coils before replacing the CDI unit. The carburetor heating chart covers heater resistance, thermo switch continuity during heating and cooling, and when to replace the rectifier/regulator.

Exploded Views, Tools, and Specifications

The clutch removal, crankcase separation, transmission removal, and wheel and drum brake views pair exploded drawings with part names, quantities, and job notes. The removal charts help identify which parts need to come off for a specific job. Reference tables give fastener torques, capacities, clearances, wear limits, and electrical test values.

The special-tool lists identify the clutch holding tool 90890-04086, flywheel puller 90890-01362, ignition checker 90890-06754, and fork seal driver components 90890-01184 and 90890-01186. The U.S. and Canadian flywheel puller reference changes from YU-33270 in the 2000 edition to YU-33270-B in the later editions.

Valve Clearance and Chain Slack Preview

All three editions specify cold valve clearance of 0.05–0.09 mm on the intake and 0.08–0.12 mm on the exhaust, measured at top dead center on the compression stroke.

The drive chain adjustment section specifies 40–53 mm of slack midway between the drive axle and rear wheel axle, with the rear wheel raised and the chain at its tightest point.