2012 Na Yamaha Super Tenere Manual

							
haha ABS (Anti-Lock Brake System)
4-68
EAS23P1014
REMOVING THE HYDRAULIC UNIT 
ASSEMBLY
NOTICE
ECA23P1023
Unless necessary, avoid removing and in-
stalling the brake pipes of the hydraulic unit 
assembly.
WARNING
EWA13930
Refill with the same type of brake fluid that is 
already in the system. Mixing fluids may re-
sult in a harmful chemical reaction, leading 
to poor braking performance.
NOTICE
ECA23P1024
 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.
 Do not set the main switch to  “ON ” when 
removing the hydraulic unit assembly.
 Do not clean with compressed air.
 Do not reuse the brake fluid.
 Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
 Do not allow any brake fluid to contact the 
couplers. Brake fluid may damage the cou-
plers and cause bad contacts.
 If the brake pipe flare nuts for the hydraulic 
unit assembly have been removed, be sure 
to tighten them to the specified torque and 
bleed the brake system.
1. Disconnect: ABS ECU coupler  “1”
TIP
While pushing the portion  “a” of the ABS ECU 
coupler, push the lock lever down to release the 
lock.
NOTICE
ECA23P1053
Do not use a tool to disconnect the ABS ECU 
coupler. 2. Remove:
Brake hoses
 Brake pipes
TIP
Do not operate the brake lever and brake pedal 
while removing the brake hoses and brake 
pipes.
 Do not bend the brake pipe when loosening the 
brake pipe flare nuts.
NOTICE
ECA23P1025
When removing the brake hoses and brake 
pipes, cover the area around the hydraulic 
unit assembly to catch any spilt brake fluid. 
Do not allow the brake fluid to contact other 
parts.
 Before disconnecting the brake pipes from 
the hydraulic unit assembly, do not lift up 
or move the brake pipes.
3. Remove: Hydraulic unit assembly “1”
TIP
To avoid brake fluid leakage and to prevent for-
eign materials from entering the hydraulic unit 
assembly, insert a rubber plug  “a” or a bolt (M10 
× 1.00) into each flare nut hole.
NOTICE
ECA23P1026
When using a bolt, do not tighten the bolt un-
til the bolt head touches the hydraulic unit. 
Otherwise, the brake pipe seating surface 
could be deformed.
1a  
						

							
haha ABS (Anti-Lock Brake System)
4-69
EAS23P1015
CHECKING THE HYDRAULIC UNIT 
ASSEMBLY
1. Check: Hydraulic unit assembly
Cracks/damage   Replace the hydraulic unit 
assembly and the brake pipes that are con-
nected to the assembly as a set.
EAS23P1016
CHECKING THE BRAKE PIPES
The following procedure applies to all of the 
brake pipes.
1. Check: Brake pipe end (flare nut)
Damage   Replace the hydraulic unit as-
sembly, brake pipes, and related parts as a 
set.
EAS23P1017
INSTALLING THE HYDRAULIC UNIT 
ASSEMBLY
1. Assemble: Hydraulic unit assembly
 Hydraulic unit brake pipes
 Hydraulic unit brake pipe joint
TIP
Do not allow any foreign materials to enter the 
hydraulic unit assembly or the brake hoses or 
brake pipes when installing the hydraulic unit as-
sembly.
NOTICE
ECA23P1027
Do not remove the rubber plugs or bolts 
(M10 ×  1.00) installed in the flare nut holes 
before installing the hydraulic unit assem-
bly.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the rubber plugs or bolts (M10  × 
1.00).
b. Assemble the hydraulic unit assembly, hy- draulic unit brake pipes, and hydraulic unit 
brake pipe joint.
TIP
Temporarily tighten the brake pipe flare nuts.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Install: Hydraulic unit assembly
 Hydraulic unit brake pipe joint
(to the rear fender)
3. Tighten: Hydraulic unit brake pipe flare nuts
NOTICE
ECA23P1028
If the brake pipe flare nut does not turn easi-
ly, replace the hydraulic unit assembly, 
brake pipes, and related parts as a set.
TIP
Do not bend the brake pipe when tightening the 
brake pipe flare nuts.
4. Install:
Rear fender assembly
(to the rear frame)
5. Install: Gaskets 
 Brake hose union bolts
 Brake hoses  “1”
a
1
T R..  Hydraulic unit assembly bolt
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
Hydraulic unit brake pipe joint 
bolt 7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
T R.. Hydraulic unit brake pipe flare 
nut
16 Nm (1.6 m ·kgf, 12 ft· lbf)
T R..  Rear fender assembly bolt
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
New   
						

							
haha ABS (Anti-Lock Brake System)
4-70
NOTICE
ECA23P1029
When installing each brake hose onto the hy-
draulic unit brake pipe joint (four locations), 
make sure that the brake pipe  “a” touches 
the projection “b”  on the joint.
TIP
Except for the brake hose (front brake master 
cylinder to hydraulic unit brake pipe joint), each 
brake hose is color-coded to its corresponding 
projection on the hydraulic unit brake pipe joint 
(three locations); therefore, be sure to match the 
paint colors “c” and “d”.
6. Connect: ABS ECU coupler  “1”
TIP
Pull the lock lever up until a click is heard, mak-
ing sure that the ABS ECU coupler is installed 
securely.
7. Fill:
Brake master cylinder reservoir
 Brake fluid reservoir
(with the specified amount of the specified 
brake fluid)
WARNING
EWA23P1007
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 master cylinder reser-
voir or brake fluid reservoir. Water will sig-
nificantly 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.
8. Bleed:
Brake system
Refer to “ BLEEDING THE HYDRAULIC 
BRAKE SYSTEM (ABS) ” on page 3-14.
9. Check the operation of the hydraulic unit ac- cording to the brake lever and the brake ped-
al response. (Refer to  “HYDRAULIC UNIT 
OPERATION TESTS ” on page 4-70.)
NOTICE
ECA14770
Always check the operation of the hydraulic 
unit according to the brake lever and the 
brake pedal response.
10.Delete the fault codes. (Refer to  “[D-1] DE-
LETING THE FAULT CODES ” on page 
8-119.)
11.Perform a trial run. (Refer to  “TRIAL RUN ” on 
page 4-74.)
EAS22800
HYDRAULIC UNIT OPERATION TESTS
The reaction-force pulsating action generated in 
the brake lever and brake pedal when the ABS 
is activated can be tested when the vehicle is 
stopped.
The hydraulic unit operation can be tested using 
the following two methods.
 Hydraulic unit operation test 1: this test checks 
the function of the ABS after the system was 
disassembled, adjusted, or serviced.
T R..  Brake hose union bolt
30 Nm (3.0 m· kgf, 22 ft·lbf)
  Specified brake fluid
DOT 4
a b
d
dd
c
c
1
1  
						

							
haha ABS (Anti-Lock Brake System)
4-71
 Hydraulic unit operation test 2: this test gener-
ates the same reaction-force pulsating action 
that is generated in the brake lever and brake 
pedal when the ABS is activated.
Hydraulic unit operation test 1
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
1. Place the vehicle on the centerstand.
2. Set the main switch to  “OFF ”.
3. Remove: Rider seat
 Right side cowling
Refer to  “GENERAL CHASSIS ” on page 4-1.
4. Check:
Battery voltage
Lower than 12.8 V   Charge or replace the 
battery.
TIP
 If the battery voltage is lower than 12.8 V, 
charge the battery, and then perform hydraulic 
unit operation test 1.
 If the battery voltage is lower than 10 V, the 
ABS warning light comes on and the ABS does 
not operate.
5. Remove the protective cap, and then connect  the test coupler adapter  “1” to the ABS test 
coupler  “2”. 6. Set the main switch to 
“ON ” while operating 
the brake lever and the brake pedal simulta-
neously.
TIP
Do not push the start switch when setting the 
main switch to  “ON ”, otherwise the operation 
test will not begin.
7. Check:
Hydraulic unit operation
When the main switch is set to  “ON ”, a single 
pulse will be generated in the brake lever  “1”, 
brake pedal  “2”, and again in the brake lever 
“1” , in this order.
NOTICE
ECA23P1030
Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
 If the pulse is felt in the brake pedal before 
it is felt in the brake lever, check that the 
brake hoses and brake pipes are connected 
correctly to the hydraulic unit assembly.
  Battery voltage
Higher than 12.8 V
  Test coupler adapter
90890-03149
1
2
1
2  
						

							
haha ABS (Anti-Lock Brake System)
4-72
 If the pulse is hardly felt in either the brake 
lever or brake pedal, check that the brake 
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
If the operation of the hydraulic unit is normal, 
delete all of the fault codes.
8. Release the brake lever and brake pedal, and  then set the main switch to  “OFF ”.
NOTICE
ECA23P1089
If the main switch is set back to  “ON ” while 
the brake lever and brake pedal are operated, 
the hydraulic unit operation test cannot be 
restarted.
Hydraulic unit operation test 2
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
1. Place the vehicle on the centerstand.
2. Set the main switch to  “OFF ”.
3. Remove:
Rider seat
 Right side cowling
Refer to  “GENERAL CHASSIS ” on page 4-1.
4. Check: Battery voltage
Lower than 12.8 V   Charge or replace the 
battery.
TIP
 If the battery voltage is lower than 12.8 V, 
charge the battery, and then perform hydraulic 
unit operation test 2.
 If the battery voltage is lower than 10 V, the 
ABS warning light comes on and the ABS does 
not operate. 5. Remove the protective cap and then connect 
the test coupler adapter  “1” to the ABS test 
coupler  “2”.
6. Set the engine stop switch “1”  to “”.
7. Set the main switch to  “ON ”.
8. Push the start switch  “1” for at least 4 sec-
onds.
NOTICE
ECA14790
Do not operate the brake lever or the brake 
pedal.  Battery voltage
Higher than 12.8 V
  Test coupler adapter
90890-03149
1
2
1
1  
						

							
haha ABS (Anti-Lock Brake System)
4-73
9. After releasing the start switch, operate the  brake lever and the brake pedal simulta-
neously.
10.A reaction-force pulsating action is generated  in the brake lever  “1” 0.5 second after the 
brake lever and the brake pedal are operated 
simultaneously and continues for approxi-
mately 2.5 seconds.
TIP
 The reaction-force pulsating action consists of 
quick pulses.
 Be sure to continue operating the brake lever 
and brake pedal even after the pulsating action 
has stopped.
11.After the pulsating action has stopped in the  brake lever, it is generated in the brake pedal 
“1” 0.5 second later and continues for approx-
imately 2.5 seconds.
TIP
 The reaction-force pulsating action consists of 
quick pulses.
 Be sure to continue operating the brake lever 
and brake pedal even after the pulsating action 
has stopped. 12.After the pulsating action has stopped in the 
brake pedal, it is generated in the brake lever 
0.5 second later and continues for approxi-
mately 2.5 seconds.
TIP
The reaction-force pulsating action consists of 
quick pulses.
NOTICE
ECA23P1032
Check that the pulsating action is felt in the 
brake lever, brake pedal, and again in the 
brake lever, in this order.
 If the pulsating action is felt in the brake 
pedal before it is felt in the brake lever, 
check that the brake hoses and brake pipes 
are connected correctly to the hydraulic 
unit assembly.
 If the pulsating action is hardly felt in either 
the brake lever or brake pedal, check that 
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
13.Release the brake lever and brake pedal,  and then set the main switch to  “OFF ”.
NOTICE
ECA23P1031
If the main switch is set back to  “ON ” while 
the brake lever and brake pedal are operated, 
the hydraulic unit operation test cannot be 
restarted.
14.Remove the test coupler adapter from the  ABS test coupler, and then install the protec-
tive cap.
15.Set the main switch to  “ON ”.
16.Set the engine stop switch to “” .
17.Check for brake fluid leakage around the hy- draulic unit.
Brake fluid leakage   Replace the hydraulic 
unit assembly, brake pipes, and related parts 
as a set.
1
1  
						

							
haha ABS (Anti-Lock Brake System)
4-74
EAS22820
TRIAL RUN
After all checks and servicing are completed, al-
ways ensure the vehicle has no problems by 
performing a trial run at a speed of faster than 30 
km/h.  
						

							
haha HANDLEBAR
4-75
EAS22840
HANDLEBAR Removing the handlebar
Order Job/Parts to remove Q ’ty Remarks
Right side cowling Refer to 
“GENERAL CHASSIS ” on page 
4-1.
1 Left hand shield 1
2 Left grip end 1
3 Left rear view mirror 1
4 Left hand shield upper bracket 1
5 Clutch switch coupler 1 Disconnect.
6 Clutch switch 1
7 Clutch master cylinder holder 1
8 Clutch master cylinder assembly 1
9 Left handlebar switch 1
10 Handlebar grip 1
3.8 Nm (0.38 m
kgf, 2.8 ft 
Ibf)T.R.
27 Nm (2.7 m 
kgf, 20 ft 
Ibf)T.R.
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.
3.5 Nm (0.35 m 
kgf, 2.5 ft 
Ibf)T.R.3.5 Nm (0.35 m 
kgf, 2.5 ft 
Ibf)T.R.
3.8 Nm (0.38 m 
kgf, 2.8 ft 
Ibf)T.R.
14 Nm (1.4 m 
kgf, 10 ft 
Ibf)T.R.
17 Nm (1.7 m 
kgf, 12 ft 
Ibf)T.R.
28 Nm (2.8 m 
kgf, 20 ft 
Ibf)T.R.
4.5 Nm (0.45 m 
kgf, 3.3 ft 
Ibf)T.R.
3
4
1
78
9
10
2 65
9
LS
LS
LT
LT  
						

							
haha HANDLEBAR
4-76
Removing the handlebar Order Job/Parts to remove Q ’ty Remarks
11 Right hand shield 1
12 Right grip end 1
13 Right rear view mirror 1
14 Right hand shield upper bracket 1
15 Front brake light switch connector 2 Disconnect.
16 Front brake light switch 1
17 Front brake master cylinder holder 1
18 Front brake master cylinder assembly 1
19 Right handlebar switch 1
20 Throttle cable housing 2
21 Throttle cable 2 Disconnect.
22 Throttle grip 1
3.8 Nm (0.38 m
kgf, 2.8 ft 
Ibf)T.R.
27 Nm (2.7 m 
kgf, 20 ft 
Ibf)T.R.
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.
3.5 Nm (0.35 m 
kgf, 2.5 ft 
Ibf)T.R.3.5 Nm (0.35 m 
kgf, 2.5 ft 
Ibf)T.R.
3.8 Nm (0.38 m 
kgf, 2.8 ft 
Ibf)T.R.
14 Nm (1.4 m 
kgf, 10 ft 
Ibf)T.R.
17 Nm (1.7 m 
kgf, 12 ft 
Ibf)T.R.
28 Nm (2.8 m 
kgf, 20 ft 
Ibf)T.R.
4.5 Nm (0.45 m 
kgf, 3.3 ft 
Ibf)T.R.
21
18 13
11
16 20
20
19
2212
19
17
15 14
LS
LS
LT
LT  
						

							
haha HANDLEBAR
4-77
Removing the handlebar Order Job/Parts to remove Q ’ty Remarks
23 Upper handlebar holder 2
24 Handlebar 1
For installation, reverse the removal proce-
dure.
3.8 Nm (0.38 m 
kgf, 2.8 ft 
Ibf)T.R.
27 Nm (2.7 m 
kgf, 20 ft 
Ibf)T.R.
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.
3.5 Nm (0.35 m 
kgf, 2.5 ft 
Ibf)T.R.3.5 Nm (0.35 m 
kgf, 2.5 ft 
Ibf)T.R.
3.8 Nm (0.38 m 
kgf, 2.8 ft 
Ibf)T.R.
14 Nm (1.4 m 
kgf, 10 ft 
Ibf)T.R.
17 Nm (1.7 m 
kgf, 12 ft 
Ibf)T.R.
28 Nm (2.8 m 
kgf, 20 ft 
Ibf)T.R.
4.5 Nm (0.45 m 
kgf, 3.3 ft 
Ibf)T.R.
2323
24
LS
LS
LT
LT