2012 Na Yamaha Super Tenere Manual

							
haha FRONT BRAKE
4-38
Removing the front brake master cylinder Order Job/Parts to remove Q ’ty Remarks
10 Front brake light switch connector 2 Disconnect.
11 Front brake light switch 1
12 Brake hose union bolt 1
13 Front brake hose gasket 2
14 Brake hose (front brake master cylinder to hy-
draulic unit) 1
15 Front brake master cylinder holder 1
16 Front brake master cylinder 1
For installation, reverse the removal proce-
dure.
13
16 12
14
11
15
10New
S
LT
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
1.2 Nm (0.12 m 
kgf, 0.87 ft 
Ibf)T.R.
4.5 Nm (0.45 m 
kgf, 3.3 ft 
Ibf)T.R.
17 Nm (1.7 m 
kgf, 12 ft 
Ibf)T.R.
27 Nm (2.7 m 
kgf, 20 ft 
Ibf)T.R.
1.0 Nm (0.10 m 
kgf, 0.72 ft 
Ibf)T.R.
3.8 Nm (0.38 m 
kgf, 2.8 ft 
Ibf)T.R.
6 Nm (0.6 m 
kgf, 4.3 ft 
Ibf)T.R.
1.5 Nm (0.15 m 
kgf, 1.1 ft 
Ibf)T.R.
30 Nm (3.0 m 
kgf, 22 ft 
Ibf)T.R.  
						

							
haha FRONT BRAKE
4-39
Disassembling the front brake master cylinder Order Job/Parts to remove Q ’ty Remarks
1 Brake master cylinder kit 1
2 Brake master cylinder body 1
For assembly, reverse the disassembly pro-
cedure.
2
BF
S
New
BF
1  
						

							
haha FRONT BRAKE
4-40
Removing the front brake calipers Order Job/Parts to remove Q ’ty Remarks
The following procedure applies to both of 
the front brake calipers.
Brake fluid Drain.
Refer to 
“BLEEDING THE HYDRAULIC 
BRAKE SYSTEM (ABS) ” on page 3-14.
1 Front brake hose holder 1 Left side only.
2 Brake hose union bolt 1
3 Brake hose gasket 1 Left side only.
4 Brake hose (left front brake caliper to right front 
brake caliper) 1 Left brake caliper side.
5 Brake hose gasket 2
6 Brake hose (left front brake caliper to right front 
brake caliper) 1 Right brake caliper side.
New
New
6
1
4
5
3
2
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
30 Nm (3.0 m 
kgf, 22 ft 
Ibf)T.R.
40 Nm (4.0 m 
kgf, 29 ft 
Ibf)T.R.  
						

							
haha FRONT BRAKE
4-41
Removing the front brake calipers Order Job/Parts to remove Q ’ty Remarks
7 Brake hose (hydraulic unit to left front brake cal-
iper) 1 Left side only.
8 Front reflector 1
9 Front wheel sensor lead holder 1 Left side only.
10 Front brake caliper 1
For installation, reverse the removal proce-
dure.
8
10
7
9
7 Nm (0.7 m

kgf, 5.1 ft 
Ibf)T.R.
30 Nm (3.0 m 
kgf, 22 ft 
Ibf)T.R.
40 Nm (4.0 m 
kgf, 29 ft 
Ibf)T.R.  
						

							
haha FRONT BRAKE
4-42
Disassembling the front brake calipers Order Job/Parts to remove Q ’ty Remarks
The following procedure applies to both of 
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Front brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1 Left brake caliper side.
9 Bleed screw 1 Right brake caliper side.
For assembly, reverse the disassembly pro-
cedure.
SS
S
SBF
BF
BF
BF
5 Nm (0.5 m 
kgf, 3.6 ft 
Ibf)T.R.
5 Nm (0.5 m 
kgf, 3.6 ft 
Ibf)T.R.
New
2
7
New 6
6 5
5
6
6 7
New
New
New
New
New
1
4
3
8
9  
						

							
haha FRONT BRAKE
4-43
EAS22221
INTRODUCTION
WARNING
EWA14101
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
 Never disassemble brake components un-
less absolutely necessary.
 If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas-
sembly.
 Never use solvents on internal brake com-
ponents.
 Use only clean or new brake fluid for clean-
ing brake components.
 Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
 Avoid brake fluid coming into contact with 
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING 
THE EYES:
 Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake 
discs.
1. Remove: Front wheel
Refer to  “FRONT WHEEL ” on page 4-20.
2. Check: Brake disc
Damage/galling   Replace.
3. Measure: Brake disc deflection
Out of specification   Correct the brake disc 
deflection or replace the brake disc.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Place the vehicle on a suitable stand so that 
the front wheel is elevated.
b. Before measuring the front brake disc deflec- tion, turn the handlebar to the left or right to 
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against  the brake disc surface. e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Measure: Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification   Replace.
5. Adjust: Brake disc deflection
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by two bolt holes.
For the rear brake disc: Rotate the brake disc 
by three bolt holes.
c. Install the brake disc.
TIP
Tighten the brake disc bolts in stages and in a 
crisscross pattern.
  Brake disc deflection limit
0.10 mm (0.0039 in)
  Brake disc thickness limit
4.0 mm (0.16 in)
T R..  Brake disc bolt
18 Nm (1.8 m ·kgf, 13 ft· lbf)
LOCTITE ®    
						

							
haha FRONT BRAKE
4-44
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment  steps until the brake disc deflection is within 
specification.
f. If the brake disc deflection cannot be brought  within specification, replace the brake disc 
and brake disc bolts.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲
6. Install: Front wheel
Refer to  “FRONT WHEEL ” on page 4-20.
EAS22271
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake 
calipers.
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove: Brake pad clips  “1”
 Brake pad pin “2”
 Brake pad spring “3”
2. Remove: Brake pads “1” 3. Measure:
Brake pad wear limit  “a”
Out of specification   Replace the brake 
pads as a set.
4. Remove:  Brake caliper bolts
5. Install:  Brake pads
 Brake pad spring
TIP
Always install new brake pads and a new brake 
pad spring as a set.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect a clear plastic hose  “1” tightly to the 
bleed screw  “2”. Put the other end of the hose 
into an open container.
b. Loosen the bleed screw and push the brake  caliper pistons into the brake caliper with your 
finger.
13
2
  Brake pad lining thickness (in-
ner)
4.5 mm (0.18 in)
Limit 0.5 mm (0.02 in)
Brake pad lining thickness (out-
er) 4.5 mm (0.18 in)
Limit 0.5 mm (0.02 in)
1
a   
						

							
haha FRONT BRAKE
4-45
c. Tighten the bleed screw.
d. Install the brake pads and brake pad spring.
TIP
The arrow mark  “a” on the brake pad spring 
must point in the direction of disc rotation.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲
6. Install: Brake caliper bolts
 Brake pad pin
 Brake pad clips
7. Check: Brake fluid level
Below the minimum level mark  “a”  Add the 
specified brake fluid to the proper level.
Refer to  “CHECKING THE BRAKE FLUID 
LEVEL ” on page 3-13. 8. Check:
Brake lever operation
Soft or spongy feeling   Bleed the brake sys-
tem.
Refer to “ BLEEDING THE HYDRAULIC 
BRAKE SYSTEM (ABS) ” on page 3-14.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
TIP
Before removing the brake caliper, drain the 
brake fluid from the entire brake system.
1. Remove: Brake hose union bolt
 Brake hose gaskets
 Brake hose (left front brake caliper to right 
front brake caliper)
 Brake hose (hydraulic unit to left front brake 
caliper)
TIP
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22361
DISASSEMBLING THE FRONT BRAKE 
CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Remove:
Brake caliper pistons “1”
 Brake caliper piston dust seals  “2”
 Brake caliper piston seals “3”
T R..  Front brake caliper bleed screw
5 Nm (0.5 m ·kgf, 3.6 ft· lbf)
T R.. Front brake caliper bolt
40 Nm (4.0 m· kgf, 29 ft·lbf)
2
1
a
a  
						

							
haha FRONT BRAKE
4-46
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Blow compressed air into the brake hose joint 
opening “a”  to force out the pistons from the 
brake caliper.
WARNING
EWA23P1004
 Cover the brake caliper pistons with a rag. 
Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
 Never try to pry out the brake caliper pis-
tons.
Do not loosen the bolts “4”.
b. Remove the brake caliper piston dust seals  and brake caliper piston seals.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲
EAS22391
CHECKING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers. 1. Check:
Brake caliper pistons “1”
Rust/scratches/wear   Replace the brake 
caliper pistons.
 Brake caliper cylinders “2”
Scratches/wear   Replace the brake caliper 
assembly.
 Brake caliper body “3”
Cracks/damage   Replace the brake caliper 
assembly.
 Brake fluid delivery passages
(brake caliper body)
Obstruction   Blow out with compressed air.
WARNING
EWA13611
Whenever a brake caliper is disassembled, 
replace the brake caliper piston dust seals 
and brake caliper piston seals.
EAS22411
ASSEMBLING THE FRONT BRAKE 
CALIPERS
WARNING
EWA13621
Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake com-
ponents as they will cause the brake caliper 
piston dust seals and brake caliper piston 
seals to swell and distort.
3 2
2 1
3
2
2
1
a
4
Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Piston dust seals Every two years
Brake hoses Every four years
Brake fluid Every two years and 
whenever the brake 
is disassembled
1
1
23  
						

							
haha FRONT BRAKE
4-47
 Whenever a brake caliper is disassembled, 
replace the brake caliper piston dust seals 
and brake caliper piston seals.
EAS22440
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Install: Front brake caliper
(temporarily)
 Brake hose gaskets 
 Brake hose (hydraulic unit to left front brake 
caliper)  “1”
 Brake hose (left front brake caliper to right 
front brake caliper)  “2”
 Brake hose union bolt  “3”
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to  “CABLE 
ROUTING ” on page 2-43.
NOTICE
ECA23P1020
Left side
 When installing the brake hose  “1” onto the 
brake caliper, make sure that the brake pipe 
“a”  contacts the projection  “b” on the 
brake caliper.
 When installing the brake hose  “2” onto the 
brake caliper, make sure that the projection 
“c”  on the brake hose  “2” contacts the pro-
jection “d”  on the brake hose “1”.
Right side
 When installing the brake hose  “2” onto the 
brake caliper, make sure that the paint mark 
“e”  on the brake hose “2”  faces outward 
and that the brake pipe  “f” contacts the pro-
jection “g”  on the brake caliper.
TIP
Make sure that the left and right clearances  “h” 
between the brake hose  “2” and the front fend-
er are equal. 
Face the catch of the holder upward, and then 
close the holder until three clicks or more are 
heard.
2. Remove: Front brake caliper
3. Install: Brake pads
 Brake pad spring
 Brake pad pin
 Brake pad clips
 Front brake caliper
Refer to  “REPLACING THE FRONT BRAKE 
PADS ” on page 4-44.
4. Fill: Brake master cylinder reservoir
(with the specified amount of the specified 
brake fluid)
  Specified brake fluid
DOT 4
T R..  Brake hose union bolt
30 Nm (3.0 m· kgf, 22 ft·lbf)
New
A. Left side
B
. Right side
T R..  Front brake caliper bolt
40 Nm (4.0 m ·kgf, 29 ft· lbf)
1
2
3
a
d
b
c
A
2
f
e g
3
B
h
2