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Yamaha · Modern air-cooled single (2000-)

TT-R 90

Library entry covers 2002-2007

25 factory 37 guideline

Published source

Yamaha TT-R90 2007 Owner's Manual 3P2-28199-81 (Australia, English), periodic maintenance charts pp.6-3 to 6-5, NOTEs pp.6-3 and 6-5

Factory owner's handbook. Covers TT-R90 (3P2); 2007 Australia owner's manual 3P2-28199-81, English. Chart columns: initial 1000 km (600 mi) or 1 month or 30 hours, then odometer readings 3000 km (1800 mi) or 6 months or 90 hours and 5000 km (3000 mi) or 12 months or 150 hours. NOTE: from 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months, so items marked at both 3000 and 5000 km fall every 2000 km (1200 mi) or 6 months, and items marked at 5000 km only fall every 4000 km (2400 mi) or 12 months. No annual check column. Air cooled, carbureted, chain final drive, drum brakes front and rear (shoes).

Open the source

62 items for a 2002 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2002 Yamaha TT-R 90

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 1,200 mi or 6 months

20 items

Change engine oil

Engine

Factory

Manual: Engine oil (change, warm engine before draining). Factory: Marked at initial 1000 km (600 mi)/1 month/30 h, 3000 and 5000 km; not a dealer item; no oil filter row in the chart (p.6-3)
Chassis fasteners (check all chassis fitting and fasteners, correct if necessary)

Engine

Factory

Factory: Marked at initial, 3000 and 5000 km; dealer item (p.6-5)
Check engine breather and oil return

Engine

Factory

Manual: Crankcase breather system (check ventilation hose for cracks or damage and drain any deposits, replace if necessary). Factory: Marked at initial 1000 km (600 mi)/1 month/30 h, 3000 and 5000 km; dealer item (p.6-3)
Exhaust system (check for leakage, tighten if necessary, replace gasket(s) if necessary)

Engine

Factory

Factory: Marked at 3000 and 5000 km; not at initial; not a dealer item (p.6-3)
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug (check condition, adjust gap and clean). Factory: Marked at 3000 and 5000 km; not at initial; no replace interval printed; not a dealer item (p.6-3)
Carburetor (check engine idling speed and starter operation, adjust if necessary)

Fuel and air

Factory

Factory: Marked at initial, 3000 and 5000 km; dealer item (p.6-3)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip housing and cable (check operation and free play, adjust throttle cable free play if necessary, lubricate throttle grip housing and cable). Factory: Marked at initial, 3000 and 5000 km; dealer item (p.6-5)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter element (clean with solvent, replace if necessary). Factory: Marked at 3000 and 5000 km; not at initial; dealer item. NOTE: more frequent service if riding in unusually wet or dusty areas (p.6-3, 6-5)
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line (check fuel hoses for cracks or damage, replace if necessary). Factory: Marked at 3000 km (1800 mi)/6 months/90 h and 5000 km (3000 mi)/12 months/150 h; not at initial; dealer item (p.6-3)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check operation, adjust if necessary). Factory: Marked at initial, 3000 and 5000 km; dealer item (p.6-4)
Front fork (check operation and for grease leakage, replace if necessary)

Front end

Factory

Factory: Marked at 3000 and 5000 km; no fork oil change interval printed; dealer item (p.6-5)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm pivot bearings (check bearing assemblies for looseness, moderately repack with lithium-soap-based grease). Factory: Marked at 3000 and 5000 km; not at initial; check and repack printed together in one row; dealer item (p.6-4)
Brake lever pivot shaft (apply lithium-soap-based grease lightly)

Brakes

Factory

Factory: Marked at 3000 and 5000 km; not a dealer item (p.6-5)
Brake pedal pivot shaft (apply lithium-soap-based grease lightly)

Brakes

Factory

Factory: Marked at 3000 and 5000 km; not a dealer item (p.6-5)
Check brake pads and discs

Brakes

Factory

Manual: Front brake (check operation, adjust brake lever free play and replace brake shoes if necessary). Factory: Drum brake. Marked at initial, 3000 and 5000 km; dealer item (p.6-4)
Rear brake (check operation, adjust brake pedal free play and replace brake shoes if necessary)

Brakes

Factory

Factory: Drum brake. Marked at initial, 3000 and 5000 km; dealer item (p.6-4)
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check bearings for smooth operation, replace if necessary). Factory: Marked at 3000 and 5000 km; not at initial; dealer item (p.6-4)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth and for damage, replace if necessary, check air pressure, correct if necessary). Factory: Marked at 3000 and 5000 km; not at initial; dealer item (p.6-4)
Wheels (check runout, spoke tightness and for damage, tighten spokes if necessary)

Wheels and tires

Factory

Factory: Marked at initial, 3000 and 5000 km; dealer item (p.6-4)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control cables (apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly). Factory: Marked at initial, 3000 and 5000 km; dealer item (p.6-5)

Every 2,400 mi or 12 months

5 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance (check and adjust when engine is cold). Factory: Marked at 5000 km (3000 mi)/12 months/150 h only; dealer item (p.6-3)
Spark arrester (clean)

Engine

Factory

Factory: Marked at 5000 km (3000 mi)/12 months/150 h only; dealer item (p.6-5)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check bearing assemblies for looseness, moderately repack with lithium-soap-based grease). Factory: Marked at initial 1000 km (600 mi)/1 month/30 h and at 5000 km (3000 mi)/12 months/150 h; not at 3000 km; check and repack printed together in one row; dealer item (p.6-4)
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand pivot (check operation, apply lithium-soap-based grease lightly). Factory: Marked at initial and at 5000 km (3000 mi)/12 months/150 h; not at 3000 km; not a dealer item (p.6-5)
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assembly (check operation and for oil leakage, replace if necessary). Factory: Marked at 5000 km (3000 mi)/12 months/150 h only; dealer item (p.6-5)

Every 3,000 mi or 12 months

6 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 5,000 mi or 12 months

1 item

Replace oil filter

Engine

Guideline

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.