2012 Na Yamaha Super Tenere Manual
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haha GENERAL CHASSIS 4-18 Removing the air filter case Order Job/Parts to remove Q ’ty Remarks Rider seat Refer to “Removing the seats and carriers ”. Left side cowling/Right side panel Refer to “Removing the side cowlings, side panel, and engine guard”. 1 Air filter case cover 1 2 Air filter element 1 3 Intake air temperature sensor coupler 1 Disconnect. 4 Cylinder head breather hose 1 Disconnect. 5 Air filter case joint clamp screw 2 Loosen. 6 Air filter case 1 7 Air chamber 1 For installation, reverse the removal proce- dure. 1 (9) 2 3 4 5 5 6 7 New New 1.2 Nm (0.12 m kgf, 0.87 ft Ibf)T.R. 1.6 Nm (0.16 m kgf, 1.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 2.8 Nm (0.28 m kgf, 2.0 ft Ibf)T.R. 1.6 Nm (0.16 m kgf, 1.2 ft Ibf)T.R.
haha GENERAL CHASSIS 4-19 EAS23P1013 REMOVING THE AIR FILTER CASE 1. Remove: Fuel tank bolts “1” Air filter case TIP After removing the fuel tank bolts, lift up the front of the fuel tank. NOTICE ECA23P4001 When lifting up the fuel tank, be careful not to pull the fuel tank overflow hose and fuel tank breather hose. Make sure the fuel tank breather/overflow hose is routed correctly. 1
haha FRONT WHEEL 4-20 EAS21880 FRONT WHEEL Removing the front wheel sensor, front wheel and brake discs Order Job/Parts to remove Q ’ty Remarks Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. 1 Front wheel sensor coupler 1 Disconnect. 2 Front brake hose holder 1 3 Front wheel sensor 1 4 Front wheel sensor lead holder 1 5 Front reflector 2 6 Front brake caliper 2 7 Front wheel axle pinch bolt 2 Loosen. 8 Front wheel axle 1 9 Front wheel 1 10 Collar (right side) 1 5 4 2 6 1 6 5 7 8 (5) (5) 10 9 3 LSNew LT LT 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.18 Nm (1.8 m kgf, 13 ft Ibf)T.R. 18 Nm (1.8 m kgf, 13 ft Ibf)T.R. 21 Nm (2.1 m kgf, 15 ft Ibf)T.R. 72 Nm (7.2 m kgf, 52 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 40 Nm (4.0 m kgf, 29 ft Ibf)T.R. 40 Nm (4.0 m kgf, 29 ft Ibf)T.R. 9 Nm (0.9 m kgf, 6.5 ft Ibf)T.R.
haha FRONT WHEEL 4-21 Removing the front wheel sensor, front wheel and brake discs Order Job/Parts to remove Q ’ty Remarks 11 Front wheel sensor housing 1 12 Collar (left side) 1 13 Front brake disc 2 For installation, reverse the removal proce- dure. (5) (5) (5) (5) 13 13 12 11 LSNew LT LT 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.18 Nm (1.8 m kgf, 13 ft Ibf)T.R. 18 Nm (1.8 m kgf, 13 ft Ibf)T.R. 21 Nm (2.1 m kgf, 15 ft Ibf)T.R. 72 Nm (7.2 m kgf, 52 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 40 Nm (4.0 m kgf, 29 ft Ibf)T.R. 40 Nm (4.0 m kgf, 29 ft Ibf)T.R. 9 Nm (0.9 m kgf, 6.5 ft Ibf)T.R.
haha FRONT WHEEL 4-22 Disassembling the front wheel Order Job/Parts to remove Q ’ty Remarks 1 Oil seal 1 2 Front wheel sensor rotor 1 3 Oil seal 1 4 Wheel bearing 2 5 Spacer 1 For assembly, reverse the disassembly pro- cedure. 2 (5) 3 4 5 4 1 New New New LS LS LT 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
haha FRONT WHEEL 4-23 EAS21900 REMOVING THE FRONT WHEEL NOTICE ECA23P1004 Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the ABS system. 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Front brake calipers TIP Do not apply the brake lever when removing the brake calipers. 3. Elevate: Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated. EAS21910 DISASSEMBLING THE FRONT WHEEL NOTICE ECA23P1005 Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the wheel sensor rotor. Do not drop the wheel sensor rotor or sub- ject it to shocks. If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Remove: Oil seals Wheel bearings ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. TIP To prevent damaging the wheel, place a rag “2” between the screwdriver and the surface of the wheel. c. Remove the wheel bearings “3” with a gener- al bearing puller. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS21932 CHECKING THE FRONT WHEEL 1. Check: Wheel axle Roll the wheel axle on a flat surface. Bends Replace. WARNING EWA13460 Do not attempt to straighten a bent wheel ax- le. 2. Check: Tire 1 1 2
haha FRONT WHEEL 4-24 Front wheel Damage/wear Replace. Refer to “CHECKING THE TIRES ” on page 3-17 and “ CHECKING THE WHEELS ” on page 3-16. 3. Check: Spokes Bends/damage Replace. Loose Tighten. Refer to “CHECKING AND TIGHTENING THE SPOKES ” on page 3-16. TIP After tightening the spokes, measure the front wheel runout. 4. Measure: Front wheel radial runout “1” Front wheel lateral runout “2” Over the specified limits Replace. 5. Check: Wheel bearings Front wheel turns roughly or is loose Re- place the wheel bearings. Oil seals Damage/wear Replace. EAS22010 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR NOTICE ECA23P1006 Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. The front wheel sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the wheel sensor rotor. Do not drop or shock the wheel sensor or the wheel sensor rotor. 1. Check: Front wheel sensor “1” Cracks/bends/distortion Replace. Iron powder/dust Clean. 2. Check: Front wheel sensor rotor “1” Cracks/damage/scratches Replace the front wheel sensor rotor. Iron powder/dust/solvent Clean. TIP The wheel sensor rotor is installed on the inner side of the wheel hub. When cleaning the wheel sensor rotor, be careful not to damage the surface of the rotor magnet. Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) 1 21 1
haha FRONT WHEEL 4-25 3. Measure: Wheel sensor rotor deflection Out of specification Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor deflection, or replace the wheel sensor rotor. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Hold the dial gauge at a right angle against the wheel sensor rotor surface. b. Measure the wheel sensor rotor deflection. TIP Do not touch the surface of the rotor magnet with a sharp object. c. If the deflection is above specification, re- move the sensor rotor from the wheel, rotate it by two or three bolt holes, and then install it. NOTICE ECA23P1007 Replace the wheel sensor rotor bolts with new ones. d. If the deflection is still above specification, re- place the wheel sensor rotor. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS21960 ASSEMBLING THE FRONT WHEEL NOTICE ECA23P1008 Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the wheel sensor rotor. Do not drop the wheel sensor rotor or sub- ject it to shocks. If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: Wheel bearings ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Install the new wheel bearing (left side). NOTICE ECA23P1009 Do not contact the wheel bearing inner race “1” or balls “2”. Contact should be made only with the outer race “3”. TIP Use a socket “4” that matches the diameter of the wheel bearing outer race. b. Install the spacer. c. Install the new wheel bearing (right side). TIP Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”. Wheel sensor rotor deflection limit 0.15 mm (0.0059 in) T R.. Wheel sensor rotor bolt 8 Nm (0.8 m ·kgf, 5.8 ft· lbf) LOCTITE ® New
haha FRONT WHEEL 4-26 ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 2. Install: Front wheel sensor rotor NOTICE ECA23P1010 Replace the wheel sensor rotor bolts with new ones. 3. Measure: Wheel sensor rotor deflection Out of specification Correct the wheel sen- sor rotor deflection or replace the wheel sen- sor rotor. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ” on page 4-24. EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire, wheel, or both, the front wheel static balance should be adjusted. Adjust the front wheel static balance with the brake discs installed. 1. Remove: Balancing weight(s) 2. Find: Front wheel ’s heavy spot TIP Place the front wheel on a suitable balancing stand. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X 1” mark at the bottom of the wheel. c. Turn the front wheel 90 ° so that the “X 1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X 2” mark at the bottom of the wheel. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheel ’s heavy spot “X”. ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 3. Adjust: Front wheel static balance ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Install a balancing weight “1” onto the rim ex- actly opposite the heavy spot “X”. TIP Start with the lightest weight. b. Turn the front wheel 90° so that the heavy spot is positioned as shown. T R.. Front wheel sensor rotor bolt 8 Nm (0.8 m ·kgf, 5.8 ft· lbf) LOCTITE ® Wheel sensor rotor deflection limit 0.15 mm (0.0059 in) 1 4 5 2 3 1
haha FRONT WHEEL 4-27 c. If the heavy spot does not stay in that posi- tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. TIP Install up to four balancing weights on the rim. When installing three or four balancing weights, install the third and fourth weights on the oppo- site side of the rim. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 4. Check: Front wheel static balance ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS22000 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) 1. Install: Front brake discs TIP Tighten the brake disc bolts in stages and in a crisscross pattern. 2. Check: Front brake discs Refer to “ CHECKING THE FRONT BRAKE DISCS ” on page 4-43. 3. Lubricate: Oil seal lips 4. Install: Collars Front wheel sensor housing Front wheel TIP Align the slot “a” in the front wheel sensor hous- ing with the projection “b” of the front fork before assembly. 5. Install: Front wheel axle Front wheel axle pinch bolts NOTICE ECA23P1011 Before tightening the wheel axle, push down hard on the handlebars several times and check if the front fork rebounds smoothly. T R.. Front brake disc bolt 18 Nm (1.8 m· kgf, 13 ft·lbf) LOCTITE ® Recommended lubricant Lithium-soap-based grease T R.. Front wheel axle 72 Nm (7.2 m ·kgf, 52 ft· lbf) Front wheel axle pinch bolt 21 Nm (2.1 m ·kgf, 15 ft· lbf) a b