2012 Na Yamaha Super Tenere Manual

							
haha PERIODIC MAINTENANCE
3-4
EAS21030
CHECKING THE FUEL LINE
1. Remove: Rider seat
 Left side cowling
 Right side panel
Refer to  “GENERAL CHASSIS ” on page 4-1.
2. Remove: Fuel tank bolts  “1”
TIP
After removing the fuel tank bolts, lift up the front 
of the fuel tank.
NOTICE
ECA23P1003
When lifting up the fuel tank, be careful not 
to pull the fuel tank overflow hose and fuel 
tank breather hose.
3. Check:
Fuel hose  “1”
 Fuel tank breather hose  “2”
 Fuel tank overflow hose  “3”
Cracks/damage   Replace.
Loose connection   Connect properly.
NOTICE
ECA23P1078
Make sure the fuel tank breather/overflow 
hose is routed correctly. 4. Install:
Fuel tank bolts
5. Install: Right side panel
 Left side cowling
 Rider seat
Refer to “ GENERAL CHASSIS ” on page 4-1.
EAS20680
CHECKING THE SPARK PLUGS
The following procedure applies to all of the 
spark plugs.
1. Remove: Air filter case
Refer to “ GENERAL CHASSIS ” on page 4-1.
2. Remove:
Ignition coil
3. Remove: Spark plug
NOTICE
ECA13320
Before removing the spark plugs, blow away 
any dirt accumulated in the spark plug wells 
with compressed air to prevent it from falling 
into the cylinders.
4. Check:
Spark plug type
Incorrect   Change.
5. Check: Electrode  “1”
Damage/wear   Replace the spark plug.
 Insulator “2”
Abnormal color   Replace the spark plug.
Normal color is medium-to-light tan.
1
1
T R..  Fuel tank bolt
10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
 Manufacturer/model
NGK/CPR8EB9
2
3  
						

							
haha PERIODIC MAINTENANCE
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6. Clean: Spark plug
(with a spark plug cleaner or wire brush)
7. Measure: Spark plug gap  “a”
(with a wire thickness gauge)
Out of specification   Regap.
8. Install: Spark plug
TIP
Before installing the spark plug, clean the spark 
plug and gasket surface.
9. Install:
Ignition coil
10.Install: Air filter case
Refer to  “GENERAL CHASSIS ” on page 4-1.
EAS20490
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the 
valves.
TIP
 Valve clearance adjustment should be made 
on a cold engine, at room temperature.
 When the valve clearance is to be measured or 
adjusted, the piston must be at top dead center 
(TDC) on the compression stroke.
1. Remove: Air filter case
Refer to  “GENERAL CHASSIS ” on page 4-1. 
Throttle bodies
Refer to “ THROTTLE BODIES ” on page 7-6.
 Clutch cover
Refer to “ CLUTCH”  on page 5-51.
 Cylinder head cover
Refer to “ CAMSHAFTS ” on page 5-11.
2. Measure: Valve clearance
Out of specification   Adjust.
TIP
If the valve clearance is incorrect, record the 
measured reading.
 Measure the valve clearance in the following 
sequence.
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a. Turn the crankshaft clockwise and align the 
pickup rotor K mark  “a” and crankcase mating 
surface “b”.
(At this time, check that the intake cam lobes 
“c”  and exhaust cam lobes  “d” for cylinder #1 
are positioned as shown in the illustration. If 
the cam lobes are not positioned as shown, 
turn the crankshaft clockwise 360 degrees 
and recheck the positions of the cam lobes.)
  Spark plug gap
0.8– 0.9 mm (0.031– 0.035 in)
T R.. Spark plug
13 Nm (1.3 m· kgf, 9.4 ft·lbf)
T R..  Ignition coil bolt
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
LOCTITE ®
12
a
 Valve clearance (cold)
Intake0.10– 0.16 mm (0.0039 –0.0063 in)
Exhaust 0.22– 0.28 mm (0.0087 –0.0110 in)
Valve clearance measuring sequence Cylinder #1   #2
A. Front
#2 #1 A   
						

							
haha PERIODIC MAINTENANCE
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b. Turn the crankshaft 71 degrees in clockwise  and align the pickup rotor T mark  “e” and 
crankcase mating surface “b”.
c. Measure the valve clearance #1 with a thick- ness gauge  “1”. d. Turn the crankshaft clockwise 270 degrees 
so that the pickup rotor T mark  “e” is pointing 
up as shown in the illustration.
e. Measure the valve clearance #2 with a thick- ness gauge.▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Remove: Camshafts
TIP
Refer to  “CAMSHAFTS ” on page 5-11.
 When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
4. Adjust: Valve clearance
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a. Remove the valve lifter  “1” and the valve pad 
“2”  with a valve lapper  “3”.
TIP
Cover the timing chain opening and spark plug 
holes with a rag to prevent the valve pad from 
falling into the crankcase.
 Make a note of the position of each valve lifter 
“1”  and valve pad  “2” so that they can be in-
stalled in the correct place.
  Thickness gauge
90890-03180
Feeler gauge set YU-26900-9
a b
c
d
eb
1
  Thickness gauge
90890-03180
Feeler gauge set YU-26900-9
  Valve lapper
90890-04101
Valve lapping tool YM-A8998
e  
						

							
haha PERIODIC MAINTENANCE
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b. Calculate the difference between the speci- fied valve clearance and the measured valve 
clearance.
Example:
Specified valve clearance = 0.10 –0.16 mm 
(0.0039– 0.0063 in)
Measured valve clearance = 0.20 mm 
(0.0079 in)
0.20 mm (0.0079 in) - 0.16 mm (0.0063 in) = 
0.04 mm (0.002 in)
c. Check the thickness of the current valve pad.
TIP
The thickness  “a” of each valve pad is marked in 
hundredths of millimeters on the side that touch-
es the valve lifter.
Example:
If the valve pad is marked  “148” , the pad 
thickness is 1.48 mm (0.058 in).
d. Calculate the sum of the values obtained in  steps (b) and (c) to determine the required 
valve pad thickness and the valve pad num-
ber. Example:
1.48 mm (0.058 in) + 0.04 mm (0.002 in) = 
1.52 mm (0.060 in)
The valve pad number is 152.
e. Round off the valve pad number according to  the following table, and then select the suit-
able valve pad.
TIP
Refer to the following table for the available 
valve pads.
Example:
Valve pad number = 152
Rounded value = 150
New valve pad number = 150
f. Install the new valve pad  “1” and the valve lift-
er “2”.
TIP
 Lubricate the valve pad with molybdenum dis-
ulfide oil.
 Lubricate the valve lifter with engine oil.
 The valve lifter must turn smoothly when rotat-
ed by hand.
 Install the valve lifter and the valve pad in the 
correct place.
g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps.
a
Last digit Rounded value
0, 1, 2 0
3, 4, 5, 6 5
7, 8, 9 10
Valve pad range No. 120 –240
Valve pad thickness 1.20–
2.40 mm 
(0.0472 –0.0945 in)
Available valve pads 25 thicknesses in 
0.05 mm (0.002 in) 
increments
2
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haha PERIODIC MAINTENANCE
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TIP
 Refer to  “CAMSHAFTS ” on page 5-11.
 Lubricate the camshaft lobes and camshaft 
journals with molybdenum disulfide oil.
 First, install the exhaust camshaft.
 Align the camshaft marks with the cylinder 
head mating surface.
 Turn the crankshaft clockwise several full turns 
to seat the parts.
h. Measure the valve clearance again.
i. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is 
obtained.
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5. Install: All removed parts
TIP
For installation, reverse the removal procedure.
EAS21050
CHECKING THE CYLINDER HEAD 
BREATHER HOSE
1. Remove:
Air filter case
Refer to  “GENERAL CHASSIS ” on page 4-1.
2. Check: Cylinder head breather hose  “1”
Cracks/damage   Replace.
Loose connection   Connect properly.
NOTICE
ECA14920
Make sure the cylinder head breather hose is 
routed correctly.
3. Install:
Air filter case
Refer to  “GENERAL CHASSIS ” on page 4-1. EAS20571
SYNCHRONIZING THE THROTTLE BODIES
TIP
Before synchronizing the throttle bodies, check 
the following items:

Valve clearance
 Spark plugs
 Air filter element
 Throttle body joints
 Fuel hose
 Exhaust system
Cylinder head breather hose
Checking the throttle body synchronization
1. Stand the vehicle on a level surface.
TIP
Place the vehicle on the centerstand.
2. Disconnect: Intake air pressure sensor hose  “1”
3. Remove: Cap  “2”
4. Install: Vacuum hose  “1” (Parts No.: 5FL-14348-10)
 3-way joint  “2” (Parts No.: 68V-24376-00)
 Intake air pressure sensor hose  “3”
 Vacuum gauge hose for #1  “4”
 Vacuum gauge hose for #2  “5”
 Vacuum gauge
 Digital tachometer
T R..  Camshaft cap bolt
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
1A. Left side
B. Right side
1
A
B
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haha PERIODIC MAINTENANCE
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5. Check: Throttle body synchronization
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a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
b. Check the vacuum pressure.
If out of specification   Adjust the throttle 
body synchronization.
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Adjusting the throttle body synchronization
1. Adjust: Throttle body synchronization
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a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
b. Using the throttle body that has the bypass air  screw  “1” with a white paint mark as the stan-
dard, adjust the other throttle body by turning 
its bypass air screw in or out.
NOTICE
ECA23P1079
Do not turn the bypass air screw (white paint 
mark) of the throttle body that is the stan-
dard. 
Otherwise, the engine may run roughly at 
idle and the throttle bodies may not operate 
properly.
TIP
 Turn the cylinder #1 air screw or cylinder #2 air 
screw using the carburetor angle driver.
 After each step, rev the engine two or three 
times, each time for less than a second, and 
check the synchronization again.
 If a bypass air screw was removed, turn the 
screw in fully and be sure to synchronize the 
throttle bodies.
 If the throttle body synchronization can not be 
adjusted using the bypass air screw, clean or 
replace the throttle bodies.
 The difference in vacuum pressure between 
the throttle bodies should not exceed 1.33 kPa 
(10 mmHg).
  Vacuum gauge
90890-03094
Vacuummate YU-44456
A. Left side
B. Right side
  Engine idling speed
1050 –1150 r/min
  The difference in vacuum pres-
sure between the throttle bodies 
should not exceed 1.33 kPa (10 
mmHg).
A
1
4
3
2
5
B
  Engine idling speed
1050– 1150 r/min
  Carburetor angle driver 2
90890-03173
A
1  
						

							
haha PERIODIC MAINTENANCE
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2. Stop the engine and remove the measuring  equipment.
3. Install: Cap
 Intake air pressure sensor hose
4. Adjust: Throttle cable free play
Refer to “ CHECKING THE THROTTLE GRIP 
OPERATION ” on page 3-30.
EAS21081
CHECKING THE EXHAUST SYSTEM
1. Check: Exhaust pipe  “1”
 Muffler “2”
Cracks/damage   Replace.
 Gasket  “3”, “4”
Exhaust gas leaks   Replace.
2. Check:
Tightening torque
 Exhaust pipe nuts “5”
 Exhaust pipe bolt  “6”
 Exhaust pipe joint bolt  “7”
 Muffler bolt  “8” EAS23P4001
CHECKING THE CANISTER (for California 
only)
1. Remove:
Fuel tank
Refer to “ FUEL TANK ” on page 7-1.
2. Check: Canister
 Canister purge hose
 Fuel tank breather hose
 Canister breather hose
Cracks/damage   Replace.
3. Install:  Fuel tank
Refer to “ FUEL TANK ” on page 7-1.
EAS20961
REPLACING THE AIR FILTER ELEMENT
1. Remove: Rider seat
 Left side cowling
 Right side panel
Refer to “ GENERAL CHASSIS ” on page 4-1.
2. Remove:
Fuel tank bolts  “1”
TIP
After removing the fuel tank bolts, lift up the front 
of the fuel tank.
A. Left side
B. Right side
 
Throttle cable free play
3.0– 5.0 mm (0.12– 0.20 in)
T R.. Exhaust pipe nut
20 Nm (2.0 m· kgf, 14 ft·lbf)
Exhaust pipe bolt 20 Nm (2.0 m· kgf, 14 ft·lbf)
Exhaust pipe joint bolt 20 Nm (2.0 m· kgf, 14 ft·lbf)
Muffler bolt 47 Nm (4.7 m· kgf, 34 ft·lbf)
B
1
5 4
138
(4) 6
7
2  
						

							
haha PERIODIC MAINTENANCE
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NOTICE
ECA23P1003
When lifting up the fuel tank, be careful not 
to pull the fuel tank overflow hose and fuel 
tank breather hose.
3. Remove: Cap  “1”
 Air filter case cover  “2”
4. Remove: Air filter element  “1”
5. Check: Air filter element
Damage   Replace.
TIP
Replace the air filter element every 40000 km 
(24000 mi) of operation.
 The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.
6. Install: Air filter case cover
 Cap
NOTICE
ECA23P1035
Never operate the engine without the air filter 
element installed. Unfiltered air will cause 
rapid wear of engine parts and may damage 
the engine. Operating the engine without the 
air filter element will also affect throttle body 
synchronization, leading to poor engine per-
formance and possible overheating.
TIP
When installing the air filter element into the air 
filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks.
7. Install:
Fuel tank bolts
NOTICE
ECA23P1078
Make sure the fuel tank breather/overflow 
hose is routed correctly.
8. Install:
Right side panel
 Left side cowling
 Rider seat
Refer to “ GENERAL CHASSIS ” on page 4-1.
EAS20860
ADJUSTING THE CLUTCH LEVER
1. Adjust: Clutch lever position
(distance  “a” from the handlebar grip to the 
clutch lever)
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. While pushing the clutch lever forward, turn 
the adjusting dial “1”  until the clutch lever is in 
the desired position.
TIP
Be sure to align the setting on the adjusting dial 
with the arrow mark  “2” on the clutch lever hold-
er.
1
2
1
1
T R..  Air filter case cover screw
1.6 Nm (0.16 m ·kgf, 1.2 ft· lbf)
T R.. Fuel tank bolt
10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
Position #1 Distance “a”  is the largest.
Position #4 Distance “a”  is the smallest.  
						

							
haha PERIODIC MAINTENANCE
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EAS20890
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the vehicle on a level surface.
TIP
Place the vehicle on the centerstand.
2. Remove: Clutch master cylinder reservoir cap
 Clutch master cylinder reservoir diaphragm 
holder
 Clutch master cylinder reservoir diaphragm
Refer to  “CLUTCH”  on page 5-51.
3. Check: Clutch fluid level
Below the minimum level mark  “a”  Add the 
specified brake and clutch fluid to the proper 
level.
WARNING
EWA23P1010
 Use only the designated clutch fluid. Other 
clutch fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
clutch performance.
 Refill with the same type of clutch fluid that 
is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance. 
When refilling, be careful that water does 
not enter the clutch master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the clutch fluid and could cause 
vapor lock.
NOTICE
ECA13420
Clutch fluid may damage painted surfaces or 
plastic parts. Therefore, always clean up any 
spilt clutch fluid immediately.
TIP
In order to ensure a correct reading of the clutch 
fluid level, make sure the top of the reservoir is 
horizontal.
4. Install:
Clutch master cylinder reservoir diaphragm
 Clutch master cylinder reservoir diaphragm 
holder
 Clutch master cylinder reservoir cap
Refer to “ CLUTCH”  on page 5-51.
EAS20900
BLEEDING THE HYDRAULIC CLUTCH 
SYSTEM
WARNING
EWA13000
Bleed the hydraulic clutch system whenever:
 the system was disassembled,
 a clutch hose was loosened or removed,
 the clutch fluid level is very low,
clutch operation is faulty.
TIP
Be careful not to spill any clutch fluid or allow 
the clutch master cylinder reservoir to over-
flow.
 When bleeding the hydraulic clutch system, 
make sure there is always enough clutch fluid 
before applying the clutch lever. Ignoring this 
precaution could allow air to enter the hydraulic 
clutch system, considerably lengthening the 
bleeding procedure.
 If bleeding is difficult, it may be necessary to let 
the clutch fluid settle for a few hours. Repeat 
the bleeding procedure when the tiny bubbles 
in the hose have disappeared.
1. Bleed: Hydraulic clutch system
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fill the clutch master cylinder reservoir to the 
proper level with the specified brake and 
clutch fluid.
  Specified brake and clutch fluid
DOT 4
a
21
LOWER UPPER
a  
						

							
haha PERIODIC MAINTENANCE
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b. Install the clutch master cylinder reservoir di- aphragm.
c. Connect a clear plastic hose  “1” tightly to the 
bleed screw  “2”.
d. Place the other end of the hose into a con- tainer.
e. Slowly squeeze the clutch lever several 
times.
f. Fully squeeze the clutch lever without releas- ing it.
g. Loosen the bleed screw. This will release the  tension and cause the clutch lever to contact 
the handlebar grip.
h. Tighten the bleed screw and then release the  clutch lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the clutch fluid in 
the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the clutch master cylinder reservoir to the  proper level with the specified brake and 
clutch fluid.
Refer to  “CHECKING THE CLUTCH FLUID 
LEVEL ” on page 3-12.
WARNING
EWA13010
After bleeding the hydraulic clutch system, 
check the clutch operation.
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EAS21160
ADJUSTING THE FRONT DISC BRAKE
1. Adjust: Brake lever position
(distance  “a” from the throttle grip to the brake 
lever)
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. While pushing the brake lever forward, turn 
the adjusting dial  “1” until the brake lever is in 
the desired position.
TIP
Be sure to align the setting on the adjusting dial 
with the arrow mark  “2” on the brake lever.
WARNING
EWA13050
A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance.
NOTICE
ECA13490
After adjusting the brake lever position, 
make sure there is no brake drag.
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EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
TIP
 Place the vehicle on the centerstand.
Make sure the vehicle is upright.
2. Check: Brake fluid level
Below the minimum level mark  “a”  Add the 
specified brake fluid to the proper level.
T R..  Bleed screw
6 Nm (0.6 m· kgf, 4.3 ft·lbf)
21 Position #1
Dista
 nce “a”  is the largest.
Position #5 Distance “a”  is the smallest.
 Specified brake fluid
DOT 4
a
21