2012 Na Yamaha Super Tenere Manual
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haha CAMSHAFTS 5-16 9. Remove: Cylinder head cover “1” Cylinder head cover gasket TIP Lift up the wire harness, brake pipes, clutch pipe, and clutch hose, and then pull the cylinder head cover rearward to remove it. EAS23810 REMOVING THE CAMSHAFTS 1. Align: “ K” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Turn the crankshaft clockwise. b. Align the “K” mark “a” with the crankcase mat- ing surface “b”. TIP When the “K” mark “a” is aligned with the crank- case mating surface “b” , check that the match mark “c” on the intake camshaft sprocket and match mark “d” on the exhaust camshaft sprock- et are aligned with the cylinder head surface “e”. Also, check that the hole “f” in the intake cam- shaft is aligned with the match mark “g” on the intake camshaft cap. If the match marks or hole are not aligned, turn the crankshaft clockwise 360 degrees. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 2. Remove: Timing chain tensioner “1” Timing chain tensioner gasket 3. Remove: Camshaft caps NOTICE ECA13720 To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 1 2 3 1 a b ec de fg 1
haha CAMSHAFTS 5-17 4. Remove: Intake camshaft “1” Exhaust camshaft “2” TIP To prevent the timing chain from falling into the crankcase, fasten it with a wire “3”. 5. Remove: Intake camshaft sprocket “1” Exhaust camshaft sprocket “2” TIP While holding the intake camshaft sprocket and exhaust camshaft sprocket with the rotor holding tool “3” , loosen the intake camshaft sprocket bolts and exhaust camshaft sprocket bolts. EAS23850 CHECKING THE CAMSHAFTS 1. Check: Camshaft lobes Blue discoloration/pitting/scratches Re- place the camshaft. 2. Measure: Camshaft lobe dimensions “a” and “b” Out of specification Replace the camshaft. 3. Measure: Camshaft runout Out of specification Replace. Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235 1 2 3 31 2 3 Camshaft lobe dimensions Intake A40.250– 40.350 mm (1.5846 – 1.5886 in) Limit 40.150 mm (1.5807 in) Intake B 29.976– 30.076 mm (1.1802 – 1.1841 in) Limit 29.876 mm (1.1762 in) Exhaust A 39.250– 39.350 mm (1.5453 – 1.5492 in) Limit 39.150 mm (1.5413 in) Exhaust B 29.950– 30.050 mm (1.1791 – 1.1831 in) Limit 29.850 mm (1.1752 in)
haha CAMSHAFTS 5-18 4. Measure: Camshaft-journal-to-camshaft-cap clearance Out of specification Measure the camshaft journal diameter. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Install the camshaft into the cylinder head (without the camshaft caps). b. Position a strip of Plastigauge ® “1” onto the camshaft journal as shown. c. Install the camshaft caps. TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®. d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “1”. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 5. Measure: Camshaft journal diameter “a” Out of specification Replace the camshaft. Within specification Replace the cylinder head and the camshaft caps as a set. EAS23P1090 CHECKING THE CAMSHAFT SPROCKET 1. Check: Camshaft sprocket More than 1/4 tooth wear “a” Replace the camshaft sprocket, timing chain, and crank- shaft as a set. Camshaft runout limit 0.030 mm (0.0012 in) Camshaft-journal-to-camshaft- cap clearance 0.028 –0.062 mm (0.0011– 0.0024 in) T R.. Camshaft cap bolt 10 Nm (1.0 m· kgf, 7.2 ft·lbf) 1 Camshaft journal diameter 24.459– 24.472 mm (0.9630 – 0.9635 in) a. 1/4 tooth b. Correct 1. Timing chain roller 2. Camshaft sprocket 1
haha CAMSHAFTS 5-19 EAS23960 CHECKING THE TIMING CHAIN TENSIONERS 1. Check: Timing chain tensioner Cracks/damage Replace. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Push and insert timing chain tensioner rod “1” into the timing chain tensioner housing. TIP Push the timing chain tensioner rod in direction “a” , and turn the timing chain tensioner body “2” in direction “b” until it stops. b. Keep pressing the timing chain tensioner rod, mount clip “3” into groove “4”, and lock the timing chain tensioner rod. c. Push the timing chain tensioner rod in direc- tion “c”. d. Make sure that the timing chain tensioner rod can smoothly move out from the timing chain tensioner housing in direction “d”. If not smooth, replace the timing chain tensioner assembly. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Check: Decompression system TIP Check that the decompression pins “1” projects from the camshaft. Check that the decompression cams “2” and decompression pins “1” moves smoothly. EAS24000 INSTALLING THE CAMSHAFTS 1. Align: “ K” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Turn the crankshaft clockwise. b. Align the “K” mark “a” with the crankcase mat- ing surface “b”. TIP When piston #1 is before 71 ° of TDC on the compression stroke, align the “K” mark with the crankcase mating surface. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 2. Install: Decompressor lever pins “1” Decompressor lever #1 “2” Decompressor lever #2 “3” TIP Face the cutout “a” in each decompressor le- ver pin toward the exhaust camshaft sprocket. Install the decompressor lever pins, decom- pressor lever #1, and decompressor lever #2 in the exhaust camshaft as shown in the illustra- tion. a b 2 1 1 2 2 ab
haha CAMSHAFTS 5-20 3. Install: Intake camshaft sprocket “1” Exhaust camshaft sprocket “2” NOTICE ECA23P1077 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. TIP Install the cam lobe #1 “a” at the position shown in the illustration. Tighten the camshaft sprocket bolt with the ro- tor holding tool “3”. 4. Install: Timing chain “1” Exhaust camshaft “2” Exhaust camshaft cap NOTICE ECA23P1073 Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. TIP When installing the timing chain, start with the exhaust camshaft and be sure to keep the tim- ing chain as tight as possible on the exhaust side. Make sure the match mark “a” on the exhaust camshaft sprocket are aligned with the cylinder head edge. T R.. Camshaft sprocket bolt 24 Nm (2.4 m· kgf, 17 ft·lbf) Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235 3 11 a 2 a 3 3 11 T R.. Exhaust camshaft cap bolt 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) a21 a 31 2 3
haha CAMSHAFTS 5-21 5. Install: Timing chain “1” Intake camshaft “2” Intake camshaft caps NOTICE ECA23P1073 Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Install the timing chain onto intake camshaft sprocket, and then install the intake camshaft onto the cylinder head. TIP Make sure the match mark “a” on the intake camshaft sprocket are aligned with the cylinder head edge. Make sure that the distance between the “E” mark “b” on the exhaust camshaft sprocket and the “I” mark “c” on the intake camshaft sprocket is 4.5 timing chain links “d” as shown in the il- lustration. b. Install the intake camshaft caps and then fin- ger tighten the intake camshaft cap bolts. TIP Make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “1” : Left intake camshaft cap “2” : Center intake camshaft cap Make sure the arrow mark “e” on each intake camshaft cap points towards the right side of the engine. c. Fasten the timing chain securely to the intake camshaft sprocket “3” with a plastic locking tie “4”. d. Tighten the intake camshaft cap bolts. TIP To prevent the timing chain from skipping a tooth on the intake camshaft sprocket, do not remove the plastic locking tie before installing the timing chain tensioner. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 6. Install: Timing chain tensioner Timing chain tensioner gasket ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Push and insert timing chain tensioner rod “1” into the timing chain tensioner housing. a1 2 a1 2 1 dc bT R.. Intake camshaft cap bolt 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) e e 4 3 New
haha CAMSHAFTS 5-22 TIP Push the timing chain tensioner rod in direction “a” , and turn the timing chain tensioner body “2” in direction “a” until it stops. b. Keep pressing the timing chain tensioner rod, mount clip “3” into groove “4”, and lock the timing chain tensioner rod. c. Install the timing chain tensioner in the cylin- der block. d. Push the timing chain guide “5” as shown in the illustration to release the timing chain ten- sioner rod. e. Check that the timing chain is taut. If the chain is slack, reinstall the timing chain ten- sioner. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 7. Remove: Plastic locking tie TIP Remove the plastic locking tie that was used to fasten the timing chain to the intake camshaft sprocket. 8. Turn: Crankshaft (several turns clockwise) 9. Check: “ K” mark Make sure the “K” mark “a” on the pickup ro- tor is aligned with the crankcase mating sur- face “b”. Camshaft sprocket match mark Make sure the match marks “c” on the cam- shaft sprockets are aligned with the cylinder head mating surface “d”. Out of alignment Adjust. Refer to the installation steps above. Intake camshaft hole Make sure the hole “e” in the intake camshaft is aligned with the match mark “f” on the in- take camshaft cap. Out of alignment Adjust. Refer to the installation steps above. T R.. Timing chain tensioner bolt 10 Nm (1.0 m· kgf, 7.2 ft·lbf) a 1 2 4 3 5 a b dc cd
haha CAMSHAFTS 5-23 10.Measure: Valve clearance Out of specification Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. EAS23P1091 INSTALLING THE CYLINDER HEAD COVER 1. Install: Cylinder head cover gasket “1” (to the cylinder head cover “2”) TIP Apply Three Bond No.1541C ® “3” onto the mating surfaces of the cylinder head cover and cylinder head cover gaskets. Apply Yamaha bond No.1215 “4” onto the mat- ing surfaces of the cylinder head cover gasket and cylinder head. Install a cylinder head cover gasket “1”, and then cut the portions “a”. 2. Install: Cylinder head cover NOTICE ECA23P1074 When installing the cylinder head cover to the cylinder head, make sure that the cylin- der head cover gasket remains in place. 3. Check: Cylinder head cover gasket ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Remove the electrical components tray bolts. b. Move the electrical components tray “1” away from the engine as shown in the illustration. c. Check that the cylinder head cover gasket “2” is installed properly between the cylinder head cover and the cylinder head. d. Install the electrical components tray bolts. Refer to “ GENERAL CHASSIS ” on page 4-1. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 4. Tighten: Cylinder head cover bolts TIP Tighten the cylinder head cover bolts in stages and in a crisscross pattern. Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) ef New a 4 3 a 1 2New T R.. Cylinder head cover bolt 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) 1 22
haha CAMSHAFTS 5-24 5. Install: Brake pipe (hydraulic unit to left front brake caliper) Brake pipe (front brake master cylinder to hy- draulic unit) Clutch pipe 6. Install: Brake hose holders “1” TIP Be sure to fit the projection “a” on the outer sec- tion of the brake hose holder into the hole “b” in the inner section. 7. Install: Clutch hose holder bolt “1” TIP Insert the tab “a” on the clutch hose holder into the slot “b” in the frame. 8. Install: Brake hose joint bolt (hydraulic unit to left front brake caliper) “1” Brake hose joint bolt (front brake master cyl- inder to hydraulic unit) “2” TIP Make sure that the tab “a” on the brake hose joint bracket contacts the side of the brake hose joint “b”. 9. Install: Stator coil lead Starter motor lead Plastic bands Wire harness holder T R.. Brake hose holder bolt 7 Nm (0.7 m ·kgf, 5.1 ft· lbf) T R.. Clutch hose holder bolt 9 Nm (0.9 m ·kgf, 6.5 ft· lbf) 1 1 ab ba 1 T R.. Brake hose joint bolt (hydraulic unit to left front brake caliper) 7 Nm (0.7 m ·kgf, 5.1 ft· lbf) Brake hose joint bolt (front brake master cylinder to hydraulic unit) 9 Nm (0.9 m ·kgf, 6.5 ft· lbf) ba 1 ab2
haha CYLINDER HEAD 5-25 EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q ’ty Remarks TIP Place a suitable stand under the engine. Exhaust pipe/Muffler Refer to “ENGINE REMOVAL ” on page 5-3. Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-11. Thermostat/Coolant temperature sensor Refer to “THERMOSTAT ” on page 6-4. 1 Engine mounting bolt (front side) 4 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Timing chain guide (exhaust side) 1 For installation, reverse the removal proce- dure. 5 2 3 4 1 4 1 1 LT LT New NewNew New New EE E 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 28 Nm (2.8 m kgf, 20 ft Ibf)T.R. 15 Nm (1.5 m kgf, 11 ft Ibf)T.R. 15 Nm (1.5 m kgf, 11 ft Ibf)T.R. 75 Nm (7.5 m kgf, 54 ft Ibf)T.R. 75 Nm (7.5 m kgf, 54 ft Ibf)T.R. 75 Nm (7.5 m kgf, 54 ft Ibf)T.R. 1st 2nd Final T.R . Specified angle 215–22520 Nm (2.0 m kgf, 14 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) 1st 2nd Final 30 Nm (3.0 m kgf, 22 ft Ibf) T.R. Specified angle 180–190 20 Nm (2.0 m kgf, 14 ft Ibf)