2012 Na Yamaha Super Tenere Manual
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haha REAR BRAKE 4-58 EAS22561 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. EAS22570 CHECKING THE REAR BRAKE DISC 1. Remove: Rear wheel Refer to “REAR WHEEL ” on page 4-29. 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. Refer to “CHECKING THE FRONT BRAKE DISCS ” on page 4-43. 4. Measure: Brake disc thickness Measure the brake disc thickness at a few dif- ferent locations. Out of specification Replace. Refer to “CHECKING THE FRONT BRAKE DISCS ” on page 4-43. 5. Adjust: Brake disc deflection Refer to “ CHECKING THE FRONT BRAKE DISCS ” on page 4-43. 6. Install: Rear wheel Refer to “ REAR WHEEL ” on page 4-29. EAS22581 REPLACING THE REAR BRAKE PADS TIP When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1. Measure: Brake pad wear limit “a” Out of specification Replace the brake pads as a set. 2. Remove: Brake caliper bolts 3. Install: Brake pad supports Brake pad shims (onto the brake pads) Brake disc deflection limit 0.15 mm (0.0059 in) Brake disc thickness limit 4.5 mm (0.18 in) T R.. Brake disc bolt 23 Nm (2.3 m ·kgf, 17 ft· lbf) LOCTITE ® Brake pad lining thickness (in- ner) 5.8 mm (0.23 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (out- er) 5.8 mm (0.23 in) Limit 0.8 mm (0.03 in) a
haha REAR BRAKE 4-59 Brake pads TIP Always install new brake pads, brake pad shims and brake pad supports 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 piston into the brake caliper with your finger. c. Tighten the bleed screw. d. Install new brake pad supports, brake pad shims, and brake pads. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 4. Lubricate: Rear brake caliper bolts NOTICE ECA23P1022 Do not allow grease to contact the brake pads. Remove any excess grease. 5. Install: Rear brake caliper 6. 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. 7. Check: Brake pedal operation Soft or spongy feeling Bleed the brake sys- tem. Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) ” on page 3-14. EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Brake hose union bolt “1” Brake hose gaskets “2” Brake hose (hydraulic unit to rear brake cali- per) “3” TIP Put the end of the brake hose into a container and pump out the brake fluid carefully. EAS22601 DISASSEMBLING THE REAR BRAKE CALIPER 1. Remove: Brake caliper piston “1” Brake caliper piston dust seal “2” Brake caliper piston seal “3” T R.. Rear brake caliper bleed screw 6 Nm (0.6 m ·kgf, 4.3 ft· lbf) Recommended lubricant Silicone grease T R.. Rear brake caliper bolt 27 Nm (2.7 m· kgf, 19 ft·lbf) 1 2 a 1 3 2
haha REAR BRAKE 4-60 ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. WARNING EWA13550 Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. Never try to pry out the brake caliper pis- ton. b. Remove the brake caliper piston dust seal and brake caliper piston seal. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS22642 CHECKING THE REAR BRAKE CALIPER 1. Check: Brake caliper pistons “1” Rust/scratches/wear Replace the brake caliper pistons. Brake caliper cylinder “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 EWA23P1005 Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. 2. Check: Brake caliper bracket Cracks/damage Replace. EAS22651 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA23P1006 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 seal and brake caliper piston seal to swell and distort. Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: Rear brake caliper bracket Rear wheel axle Rear wheel axle nut 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 32 a Specified brake fluid DOT 4 1 2 3
haha REAR BRAKE 4-61 TIP Align the slot “a” of the rear wheel sensor hous- ing “1” with the projection “b” of the rear brake caliper bracket “2”, and then assemble them. NOTICE ECA14470 Make sure there are no foreign materials in the wheel hub. Foreign materials cause dam- age to the inner sensor rotor and wheel sen- sor. 2. Tighten: Brake torque rod bolt Rear wheel axle nut Rear wheel axle pinch bolt 3. Install: Brake pad supports Brake pad shims (onto the brake pads) Brake pads Brake caliper bolts Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS ” on page 4-58. 4. Install: Brake hose gaskets Brake hose (hydraulic unit to rear brake cali- per) “1” Brake hose union bolt “2” WARNING EWA13530 Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “CABLE ROUTING ” on page 2-43. NOTICE ECA23P1060 When installing the brake hose onto the brake caliper “3” , make sure the brake pipe “a” is installed between the projections “b” on the brake caliper. 5. Fill: Brake fluid reservoir (with the specified amount of the specified brake fluid) WARNING EWA13090 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: Brake system Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) ” on page 3-14. T R.. Brake torque rod bolt 30 Nm (3.0 m· kgf, 22 ft·lbf) Rear wheel axle nut 125 Nm (12.5 m ·kgf, 90 ft ·lbf) Rear wheel axle pinch bolt 25 Nm (2.5 m· kgf, 18 ft·lbf) T R.. Brake caliper bolt 27 Nm (2.7 m· kgf, 19 ft·lbf) T R.. Brake hose union bolt 30 Nm (3.0 m· kgf, 22 ft·lbf) ab 2 1 New Specified brake fluid DOT 4 3 1 a b 2
haha REAR BRAKE 4-62 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 pedal operation Soft or spongy feeling Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: Brake hose union bolt “1” Brake hose gaskets “2” Brake hose (rear brake master cylinder to hy- draulic unit) “3” TIP To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. EAS23P1070 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Remove: Adjuster rod pin “1” Rear brake master cylinder joint “2” TIP Remove the adjuster rod pin, and then remove the rear brake master cylinder joint. EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: Brake master cylinder Damage/scratches/wear Replace. Brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 2. Check: Brake master cylinder kit Damage/scratches/wear Replace. 3. Check: Brake fluid reservoir Cracks/damage Replace. Brake fluid reservoir diaphragm Cracks/damage Replace. 4. Check: Brake hose Cracks/damage/wear Replace. EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 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. a 1 2 3 Specified brake fluid DOT 4 2 1
haha REAR BRAKE 4-63 1. Install: Brake hose joint Brake master cylinder kit Rear brake master cylinder joint TIP The rear brake master cylinder joint installation length “a” should be 76.3– 77.3 mm (3.00–3.04 in). 2. Install: Adjuster rod pin “1” EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: Rear brake light switch “1” TIP The rear brake light switch installation length “a” should be 4.3 –5.3 mm (0.17– 0.21 in). Install the rear brake light switch spring “2” as shown in the illustration. 2. Install: Brake hose gaskets Brake hose (rear brake master cylinder to hy- draulic unit) “1” Brake hose union bolt “2” WARNING EWA13530 Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “CABLE ROUTING ” on page 2-43. NOTICE ECA14160 When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a” as shown. 3. Fill: Brake fluid reservoir (with the specified amount of the specified brake fluid) WARNING EWA13090 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. New a New 1New a 2 1 T R.. Brake hose union bolt 30 Nm (3.0 m ·kgf, 22 ft· lbf) Specified brake fluid DOT 4 New a 1 2
haha REAR BRAKE 4-64 NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. 5. 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. 6. Check: Brake pedal operation Soft or spongy feeling Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. 7. Adjust: Rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH ” on page 3-29. a
haha ABS (Anti-Lock Brake System) 4-65 EAS22760 ABS (Anti-Lock Brake System) Removing the rear fender assembly and brake hoses Order Job/Parts to remove Q ’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) ” on page 3-14. Tail/brake light assembly/Seat lock Refer to “GENERAL CHASSIS ” on page 4-1. Rear brake fluid reservoir Refer to “REAR BRAKE” on page 4-51. Fuel tank bracket Refer to “FUEL TANK ” on page 7-1. 1 ABS ECU coupler 1 Disconnect. 2 Brake hose union bolt/Gasket 1/2 3 Brake hose (front brake master cylinder to hy- draulic unit brake pipe joint) 1 Disconnect. 4 Brake hose union bolt/Gasket 1/2 1 2 2 3 44 New New New New 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 30 Nm (3.0 m kgf, 22 ft Ibf)T.R. 30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
haha ABS (Anti-Lock Brake System) 4-66 Removing the rear fender assembly and brake hoses Order Job/Parts to remove Q ’ty Remarks 5 Brake hose (hydraulic unit brake pipe joint to left front brake caliper) 1 Disconnect. 6 Brake hose union bolt/Gasket 1/2 7 Brake hose (hydraulic unit brake pipe joint to rear brake caliper) 1 Disconnect. 8 Brake hose union bolt/Gasket 1/2 9 Brake hose (rear brake master cylinder to hy- draulic unit brake pipe joint) 1 Disconnect. 10 Rear fender assembly 1 11 Rear mudguard 1 For installation, reverse the removal proce- dure. 8 97 6 10 11 5 6 New New New New 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 30 Nm (3.0 m kgf, 22 ft Ibf)T.R. 30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
haha ABS (Anti-Lock Brake System) 4-67 Removing the hydraulic unit assembly Order Job/Parts to remove Q ’ty Remarks 1 Hydraulic unit brake pipe joint 1 2 Hydraulic unit brake pipe 4 3 Hydraulic unit assembly 1 4 Rear fender 1 For installation, reverse the removal proce- dure. 1 2 2 4 3 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 16 Nm (1.6 m kgf, 12 ft Ibf)T.R. 16 Nm (1.6 m kgf, 12 ft Ibf)T.R.16 Nm (1.6 m kgf, 12 ft Ibf)T.R.