2012 Na Yamaha Super Tenere Manual
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haha SHAFT DRIVE 4-118 8. Install: Rear wheel Refer to “REAR WHEEL ” on page 4-29. 9. Fill: Final gear case Refer to “CHECKING THE FINAL GEAR OIL LEVEL ” on page 3-28.
haha 5 ENGINE ENGINE INSPECTION .................................................................................... 5-1 MEASURING THE COMPRESSION PRESSURE .................................... 5-1 ENGINE REMOVAL ........................................................................................ 5-3 REMOVING THE ENGINE ........................................................................ 5-9 INSTALLING THE ENGINE....................................................................... 5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER.............................. 5-10 CAMSHAFTS ................................................................................................. 5-11 REMOVING THE CYLINDER HEAD COVER ......................................... 5-15 REMOVING THE CAMSHAFTS.............................................................. 5-16 CHECKING THE CAMSHAFTS .............................................................. 5-17 CHECKING THE CAMSHAFT SPROCKET ............................................ 5-18 CHECKING THE TIMING CHAIN TENSIONERS ................................... 5-19 CHECKING THE DECOMPRESSION SYSTEM..................................... 5-19 INSTALLING THE CAMSHAFTS ............................................................ 5-19 INSTALLING THE CYLINDER HEAD COVER ....................................... 5-23 CYLINDER HEAD .......................................................................................... 5-25 REMOVING THE CYLINDER HEAD....................................................... 5-26 CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-26 CHECKING THE CYLINDER HEAD ....................................................... 5-26 INSTALLING THE CYLINDER HEAD ..................................................... 5-26 VALVES AND VALVE SPRINGS .................................................................. 5-28 REMOVING THE VALVES ...................................................................... 5-29 CHECKING THE VALVES AND VALVE GUIDES .................................. 5-29 CHECKING THE VALVE SEATS ............................................................ 5-31 CHECKING THE VALVE SPRINGS........................................................ 5-33 CHECKING THE VALVE LIFTERS ......................................................... 5-33 INSTALLING THE VALVES .................................................................... 5-33 CYLINDER AND PISTONS ........................................................................... 5-36 REMOVING THE PISTONS .................................................................... 5-37 CHECKING THE CYLINDERS AND PISTONS ...................................... 5-37 CHECKING THE PISTON RINGS........................................................... 5-38 CHECKING THE PISTON PINS.............................................................. 5-39 INSTALLING THE PISTONS AND CYLINDER ....................................... 5-39 GENERATOR AND STARTER CLUTCH ...................................................... 5-42 REMOVING THE GENERATOR ............................................................. 5-44 REMOVING THE STARTER CLUTCH ................................................... 5-44 CHECKING THE STARTER CLUTCH .................................................... 5-44 CHECKING THE TORQUE LIMITER ...................................................... 5-45 INSTALLING THE STARTER CLUTCH .................................................. 5-45 INSTALLING THE GENERATOR............................................................ 5-45
haha ELECTRIC STARTER................................................................................... 5-47 CHECKING THE STARTER MOTOR ..................................................... 5-49 ASSEMBLING THE STARTER MOTOR ................................................. 5-50 CLUTCH ........................................................................................................ 5-51 REMOVING THE CLUTCH ..................................................................... 5-59 CHECKING THE FRICTION PLATES..................................................... 5-60 CHECKING THE CLUTCH PLATES ....................................................... 5-60 CHECKING THE CLUTCH SPRING PLATE........................................... 5-60 CHECKING THE CLUTCH HOUSING .................................................... 5-61 CHECKING THE CLUTCH BOSS ........................................................... 5-61 CHECKING THE PRESSURE PLATE .................................................... 5-61 CHECKING THE CLUTCH PUSH RODS ............................................... 5-61 CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-61 INSTALLING THE CLUTCH .................................................................... 5-62 DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-63 CHECKING THE CLUTCH MASTER CYLINDER................................... 5-64 ASSEMBLING THE CLUTCH MASTER CYLINDER .............................. 5-64 INSTALLING THE CLUTCH MASTER CYLINDER................................. 5-64 REMOVING THE CLUTCH RELEASE CYLINDER ................................ 5-65 ASSEMBLING THE CLUTCH RELEASE CYLINDER............................. 5-66 INSTALLING THE CLUTCH RELEASE CYLINDER ............................... 5-66 PICKUP ROTOR ............................................................................................ 5-68 REMOVING THE PICKUP ROTOR ........................................................ 5-69 INSTALLING THE PICKUP ROTOR ....................................................... 5-69 SHIFT SHAFT ................................................................................................ 5-71 CHECKING THE SHIFT SHAFT ............................................................. 5-73 CHECKING THE STOPPER LEVER ...................................................... 5-73 INSTALLING THE SHIFT SHAFT ........................................................... 5-73 ADJUSTING THE SHIFT PEDAL ............................................................ 5-73 OIL PUMP ...................................................................................................... 5-75 REMOVING THE OIL PAN AND OIL STRAINER COVER ..................... 5-79 CHECKING THE OIL PUMP ................................................................... 5-79 CHECKING THE RELIEF VALVE ........................................................... 5-79 CHECKING THE OIL PIPE ..................................................................... 5-79 CHECKING THE OIL STRAINER ........................................................... 5-80 ASSEMBLING THE OIL PUMP ............................................................... 5-80 INSTALLING THE OIL PAN .................................................................... 5-80 INSTALLING THE OIL STRAINER COVER............................................ 5-80
haha CRANKCASE................................................................................................ 5-81 REMOVING THE REAR BALANCER ..................................................... 5-86 DISASSEMBLING THE CRANKCASE.................................................... 5-86 CHECKING THE CRANKCASE .............................................................. 5-87 CHECKING THE REAR BALANCER ...................................................... 5-87 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE (INTAKE SIDE) .........................................................................\ .............. 5-87 CHECKING THE OIL NOZZLES ............................................................. 5-87 ASSEMBLING THE CRANKCASE.......................................................... 5-87 INSTALLING THE REAR BALANCER .................................................... 5-91 CRANKSHAFT AND BALANCER ................................................................ 5-92 REMOVING THE FRONT BALANCER SHAFT ...................................... 5-94 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS .............. 5-94 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ...................... 5-94 REMOVING THE CONNECTING RODS ................................................ 5-94 CHECKING THE CRANKSHAFT ............................................................ 5-94 CHECKING THE CONNECTING RODS ................................................. 5-96 CHECKING THE FRONT BALANCER.................................................... 5-97 INSTALLING THE CONNECTING RODS ............................................... 5-99 INSTALLING THE CRANKSHAFT ........................................................ 5-100 INSTALLING THE FRONT BALANCER SHAFT ................................... 5-101 TRANSMISSION .......................................................................................... 5-102 REMOVING THE TRANSMISSION ...................................................... 5-108 CHECKING THE SHIFT FORKS........................................................... 5-108 CHECKING THE SHIFT DRUM ASSEMBLY ........................................ 5-108 CHECKING THE TRANSMISSION ....................................................... 5-108 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ............................ 5-109 INSTALLING THE TRANSMISSION ..................................................... 5-110 MIDDLE GEAR ............................................................................................ 5-112 REMOVING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY......... 5-116 DISASSEMBLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY ........................................................................\ .................. 5-116 REMOVING THE MIDDLE DRIVE PINION GEAR ASSEMBLY ........... 5-116 DISASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY ........................................................................\ .................. 5-116 CHECKING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY ......... 5-117 CHECKING THE MIDDLE DRIVE PINION GEAR ASSEMBLY ............ 5-117 ASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY ....... 5-117 INSTALLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY .......... 5-118 ASSEMBLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY ..... 5-118 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY ....... 5-119 MEASURING THE MIDDLE GEAR BACKLASH................................... 5-120 ADJUSTING THE MIDDLE GEAR BACKLASH .................................... 5-120 ALIGNING THE MIDDLE GEAR ........................................................... 5-122
haha ENGINE INSPECTION 5-1 EAS23P1087 ENGINE INSPECTION EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. TIP Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance Out of specification Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Remove: Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. 4. Disconnect: Ignition coil couplers “1” 5. Remove: Ignition coils “2” 6. Remove: Spark plug NOTICE ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinders. 7. Install: Extension “1” Compression gauge “2” 8. Measure: Compression pressure Out of specification Refer to steps (c) and (d). ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Turn the main switch to “ON ”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING EWA12940 To prevent sparking, ground all spark plug leads before cranking the engine. TIP The difference in compression pressure be- tween cylinders should not exceed 100 kPa (1 kg/cm ², 14 psi). c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits Eliminate. d. If the compression pressure is below the min- imum specification, pour a teaspoonful of en- gine oil into the spark plug bore and measure again. 2 1 1 2 Extension 90890-04136 Compression gauge 90890-03081 Engine compression tester YU-33223 Standard compression pressure (at sea level) 680 kPa/250 r/min (6.8 kgf/cm² /250 r/min, 96.7 psi/250 r/min) Minimum –maximum 590– 760 kPa (5.9– 7.6 kgf/cm², 83.9– 108.1 psi) 2 1
haha ENGINE INSPECTION 5-2 Refer to the following table. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 9. Install: Spark plug 10.Install: Ignition coil 11.Connect: Ignition coil couplers 12.Install: Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston ring(s) wear or damage Repair. Same as without oil Pistons, valves, cylin- der head gasket or piston ring(s) possi- bly defective Re- pair. 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 ®
haha ENGINE REMOVAL 5-3 EAS23711 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q ’ty Remarks Right side cowling/Engine guard Refer to “GENERAL CHASSIS ” on page 4-1. 1Muffler cover 1 2 Left passenger footrest 1 3 Muffler protector 1 4 Exhaust pipe joint bolt 1 5 Rubber cover 1 6Muffler 1 7Collar 1 8 Rubber damper 1 9Gasket 1 10 O 2 sensor #1 coupler 1 Disconnect. 10 4 95 8 6 1 32 7 (4) New LT 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 28 Nm (2.8 m kgf, 20 ft Ibf)T.R. 47 Nm (4.7 m kgf, 34 ft Ibf)T.R. 45 Nm (4.5 m kgf, 33 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R.
haha ENGINE REMOVAL 5-4 Removing the exhaust pipe Order Job/Parts to remove Q ’ty Remarks 11 O 2 sensor #2 coupler 1 Disconnect. 12 Exhaust pipe protector 1 13 Exhaust pipe 1 14 Gasket 2 For installation, reverse the removal proce- dure. 11 12 13 14 (4) New LT 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 28 Nm (2.8 m kgf, 20 ft Ibf)T.R. 47 Nm (4.7 m kgf, 34 ft Ibf)T.R. 45 Nm (4.5 m kgf, 33 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R.
haha ENGINE REMOVAL 5-5 Disconnecting the leads Order Job/Parts to remove Q ’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL ” on page 3-24. Drive shaft Refer to “SHAFT DRIVE ” on page 4-103. Clutch hose Disconnect. Refer to “CLUTCH ” on page 5-51. Shift arm Refer to “SHIFT SHAFT” on page 5-71. Radiator Refer to “RADIATOR ” on page 6-1. Thermostat Refer to “THERMOSTAT ” on page 6-4. Radiator outlet pipe Refer to “WAT ER P UM P ” on page 6-6. Canister Refer to “FUEL TANK ” on page 7-1. (for Cal- ifornia only) 1 Sidestand switch coupler 1 Disconnect. 2 Sidestand 1 3 Ignition coil coupler 4 Disconnect. 1 3 3 2 LT 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R. 63 Nm (6.3 m kgf, 46 ft Ibf)T.R.