Yamaha TT-R90 & TT-R90E 2003–2006 Owner's Service Manual Set (P/N 5HN-28199-83)

Match your Yamaha's factory model code to the appropriate volume. In the combined volumes, separate cable-routing and wiring diagrams show the differences between the two starting systems.

Model and repair coverage: For 2005 and 2006, the TT-R90E is the only version with a listed U.S. model code. Yamaha's model-name tables use TT-R90 and TT-R90E without the letter suffix for Europe and South Africa. Service coverage for the gas-charged Monocross rear shock is limited to inspection, removal and installation, and spring preload adjustment.

PDF Download and Navigation

Text search, bookmarks, and diagrams: All five PDFs have searchable text. The four 2003–2005 files have bookmarks to the contents and clickable entries to reach service topics. The 2006 file has direct bookmarks to individual sections. Zoom in to read small wire color codes and connector labels.

The ZIP contains five printable PDFs in English, French, and German, totaling 1,746 pages. That total includes each volume's front and back covers, one blank page, and three maintenance-record pages.

Engine, Chassis, and Electrical Service

This selection of service topics includes routine maintenance and workshop repairs. The 2006 volume also covers cleaning and storage.

• Periodic maintenance: Pre-operation checks, service intervals, lubrication, engine oil service, air filter cleaning, and adjustments for the throttle cable, valves, and drive chain.
• Carburetor and top end: Carburetor removal and fuel-level checks, cylinder head and cam timing, rocker arms, valve and spring inspection, and piston and ring service.
• Clutch and transmission: Clutch inspection and release adjustment, kick and shift shafts, oil pump inspection, CDI magneto rotor removal, crankcase separation, and crankshaft and transmission service.
• Wheels and chassis: Front and rear drum brakes, wheel bearings, front fork teardown and seal installation, handlebar and steering-bearing service, and swingarm removal.
• Electrical diagnosis: No-spark and carburetor heater troubleshooting, plus TT-R90E starter clutch inspection, starter motor disassembly and repair, and charging system tests.

Yamaha wrote these manuals for mechanics and uses exploded views and job charts to identify parts and flag work that requires special tools.

Engine Setup and Reassembly

For the Mikuni VM16SH carburetor, the manuals cover float-bowl fuel level, pilot air screw adjustment, and idle speed. The cylinder head procedures explain valve-seat contact inspection and lapping. The camshaft notes warn that crankshaft rotation during installation can cause damage or alter valve timing.

The crankcase assembly section warns that sealant can obstruct the oil gallery. Transmission procedures cover the mainshaft and drive axle, including inspection and reassembly of the gears and shift components.

Drum Brakes and Steering

The wheel procedures pair brake-shoe and drum wear limits with wheel-bearing removal and installation. Routine chassis checks include brake free play, spoke tension, wheel condition, and steering-head adjustment.

The manuals call for secure support during wheel, fork, steering, swingarm, and shock work. They also give precautions for handling the battery and refueling around a hot engine.

Ignition, Starting, and Charging Faults

The ignition chart uses spark-gap and coil tests to narrow down a no-spark fault. The carburetor heating chart covers the thermo switch, heater element, and magneto checks.

On the TT-R90E, the no-crank chart helps distinguish a starter motor fault from a problem with the battery, fuse, neutral switch, starting circuit cut-off relay, or starter relay. The charging section covers battery charging, wiring checks, and charging voltage. Routine electrical checks include the spark plug and fuse.

Identification, Tools, and Reference Data

Each volume covers general information, specifications, periodic inspection and adjustment, engine, chassis, and electrical service. The identification pages show where to find the VIN and engine serial number, plus the key identification number on TT-R90E models.

Tool references give North American and 90890-series numbers. Examples include the rocker-shaft slide hammer set (YU-1083-A / 90890-01084 and 90890-01085), valve spring compressor (YM-4019 / 90890-04019), and flywheel puller (YU-33270-B / 90890-01362). The fork and electrical procedures also identify the damper rod holder (YM-1300 / 90890-01294) and pocket tester (YU-3112-C / 90890-03112).

Specification tables provide torque values, fluid capacities, clearances, wear limits, and electrical test data for inspection and reassembly.

Sample Valve, Fork, and Ignition Specs

For valve adjustment with the engine cold, the intake clearance is 0.05–0.09 mm and the exhaust clearance is 0.08–0.12 mm.

The front fork assembly section specifies 64 cm³ of oil per fork leg. For ignition diagnosis, the CDI magneto pickup coil specification is 248–372 Ω at 20 °C.