2012 Na Yamaha Super Tenere Manual

							
haha CYLINDER HEAD
5-26
EAS24120
REMOVING THE CYLINDER HEAD
1. Remove: Cylinder head bolts
TIP
Loosen the bolts in the proper sequence as 
shown.
 Loosen each bolt 1/2 of a turn at a time. After 
all of the bolts are fully loosened, remove them.
M6  × 125 mm:  “1”, “2”
 M12 ×  185 mm:  “3”–“8”
EAS23P1107
CHECKING THE TIMING CHAIN GUIDE 
(EXHAUST SIDE)
1. Check: Timing chain guide (exhaust side)
Damage/wear Replace.
EAS24170
CHECKING THE CYLINDER HEAD
1. Eliminate: Combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
Spark plug bore threads
Valve seats
2. Check: Cylinder head
Damage/scratches   Replace. 
Cylinder head water jacket
Mineral deposits/rust   Eliminate.
3. Measure:
Cylinder head warpage
Out of specification   Resurface the cylinder 
head.
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a. Place a straightedge  “1” and a thickness 
gauge “2”  across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder  head as follows.
d. Place a 400 –600 grit wet sandpaper on the 
surface plate and resurface the cylinder head 
using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder 
head several times.
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EAS24240
INSTALLING THE CYLINDER HEAD
1. Install: Cylinder head
TIP
Pass the timing chain through the timing chain 
cavity.
2. Tighten:
Cylinder head bolts 
5
3
8
7
4
6
2
1
×6×2
FWD
  Warpage limit
0.03 mm (0.0012 in)
1
2
New  
						

							
haha CYLINDER HEAD
5-27
WARNING
EWA23P1013
Replace the bolts with new ones.
TIP
Tighten the bolts using the following procedure.
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a. Lubricate the cylinder head bolts with engine 
oil.
b. Install the cylinder head bolts.
c. Tighten the cylinder head bolts in the proper 
tightening sequence as shown.
d. Tighten the cylinder head bolts, and then  tighten them further to reach the specified an-
gle in the proper tightening sequence as 
shown.
TIP
 Tighten each bolt to the specified angle before 
tightening the next bolt to the specified torque.
e. Tighten the cylinder head bolts in the proper tightening sequence as shown.
 M12 ×  185 mm:  “1”–“6”
 M6  × 125 mm:  “7”, “8”
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T R..  Cylinder head bolt 
“1”–“ 6”
1st 20 Nm (2.0 m· kgf, 14 ft·lbf)
T R.. Cylinder head bolt 
“1”–“ 6”
2nd 30 Nm (3.0 m· kgf, 22 ft·lbf)
Cylinder head bolt FinalBolt  “1”, “2” , “4”
Specified angle 215– 225°
Bolt  “3”, “5” , “6”
Specified angle 180– 190°
T R..  Cylinder head bolt 
“7”, “8”
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
4
6
1
2
5
3
7
8
×6×2
FWD  
						

							
haha VALVES AND VALVE SPRINGS
5-28
EAS24270
VALVES AND VALVE SPRINGS Removing the valves and valve springs
Order Job/Parts to remove Q ’ty Remarks
Cylinder head Refer to “CYLINDER HEAD ” on page 5-25.
1 Valve lifter 8
2 Valve pad 8
3 Valve cotter 16
4 Valve spring retainer 8
5 Valve spring 8
6 Exhaust valve 4
7 Intake valve 4
8 Valve stem seal 8
9 Valve spring seat 8
10 Valve guide 8
For installation, reverse the removal proce-
dure.
New
New
New
New
E
E
M
M
M
M
M
M
M
M
8
9
8
10
9
5
12
3
4
10
6 7
2
34
1
3 3
5  
						

							
haha VALVES AND VALVE SPRINGS
5-29
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the 
valves and related components.
TIP
Before removing the internal parts of the cylinder 
head (e.g., valves, valve springs, valve seats), 
make sure the valves properly seal.
1. Remove: Valve lifter “1”
 Valve pad  “2”
TIP
Make a note of the position of each valve lifter 
and valve pad so that they can be reinstalled in 
their original place.
2. Check:
Valve sealing
Leakage at the valve seat   Check the valve 
face, valve seat, and valve seat width.
Refer to  “CHECKING THE VALVE SEATS” 
on page 5-31.
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a. Pour a clean solvent  “a” into the intake and 
exhaust ports.
b. Check that the valves properly seal.
TIP
There should be no leakage at the valve seat  “1”.
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3. Remove: Valve cotters
TIP
Remove the valve cotters by compressing the 
valve spring with the valve spring compressor 
“1”  and the valve spring compressor attachment 
“2”.
4. Remove: Valve spring retainer “1”
 Valve spring  “2”
 Valve  “3”
 Valve stem seal  “4”
 Valve spring seat “5”
TIP
Identify the position of each part very carefully so 
that it can be reinstalled in its original place.
EAS24290
CHECKING THE VALVES AND VALVE 
GUIDES
The following procedure applies to all of the 
valves and valve guides.
  Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attach-
ment 90890-01243
Valve spring compressor adapt-
er (26 mm) YM-01253-1
35 2 1
4     
						

							
haha VALVES AND VALVE SPRINGS
5-30
1. Measure: Valve-stem-to-valve-guide clearance
Out of specification   Replace the valve 
guide.
2. Replace: Valve guide
TIP
To ease valve guide removal and installation, 
and to maintain the correct fit, heat the cylinder 
head to 100  °C (212  °F) in an oven.
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a. Remove the valve guide with the valve guide 
remover “1”. b. Install the new valve guide with the valve 
guide installer  “2” and valve guide remover 
“1”.
c. After installing the valve guide, bore the valve  guide with the valve guide reamer  “3” to ob-
tain the proper valve-stem-to-valve-guide 
clearance.
TIP
After replacing the valve guide, reface the valve 
seat.

Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter  “b”
 Valve-stem-to-valve-guide clear-
ance (intake)
0.010 –0.037 mm (0.0004– 0.0015 
in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025 –0.052 mm (0.0010– 0.0020 
in)
Limit 0.100 mm (0.0039 in)
  Valve guide position
10.7– 11.1 mm (0.42– 0.44 in)
a. Valve guide position
3       
						

							
haha VALVES AND VALVE SPRINGS
5-31
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3. Eliminate: Carbon deposits
(from the valve face and valve seat)
4. Check: Valve face
Pitting/wear   Grind the valve face.
 Valve stem end
Mushroom shape or diameter larger than the 
body of the valve stem   Replace the valve.
5. Measure: Valve margin thickness D  “a”
Out of specification   Replace the valve.
6. Measure: Valve stem runout
Out of specification   Replace the valve.
TIP
When installing a new valve, always replace 
the valve guide.
 If the valve is removed or replaced, always re-
place the valve stem seal. EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the 
valves and valve seats.
1. Eliminate:
Carbon deposits
(from the valve face and valve seat)
2. Check: Valve seat
Pitting/wear   Replace the cylinder head.
3. Measure: Valve seat width C  “a”
Out of specification   Replace the cylinder 
head.
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a. Apply Mechanic ’s blueing dye (Dykem)  “b” 
onto the valve face.
  Valve guide remover & installer 
set (
ø5.5)
90890-04016
Valve guide remover (5.5 mm) YM-01122
Valve guide installer ( ø5.5)
90890-04015
Valve guide installer (5.5 mm)
YM-04015
Valve guide reamer (5.5 mm) 90890-01196
YM-01196
  Valve margin thickness D (intake)
1.00– 1.40 mm (0.0394– 0.0551 in)
Valve margin thickness D (ex-
haust) 1.00– 1.40 mm (0.0394– 0.0551 in)
 Valve stem runout
0.010 mm (0.0004 in)
  Valve seat width C (intake)
1.10– 1.30 mm (0.0433 –0.0512 in)
Valve seat width C (exhaust) 0.90– 1.10 mm (0.0354 –0.0433 in)     
						

							
haha VALVES AND VALVE SPRINGS
5-32
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and  onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted 
one another, the blueing will have been re-
moved.
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4. Lap: Valve face
 Valve seat
TIP
After replacing the cylinder head or replacing the 
valve and valve guide, the valve seat and valve 
face should be lapped.
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a. Apply a coarse lapping compound  “a” to the 
valve face.
NOTICE
ECA13790
Do not let the lapping compound enter the 
gap between the valve stem and the valve 
guide.
b. Apply molybdenum disulfide oil onto the  valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve  seat are evenly polished, then clean off all of 
the lapping compound.
TIP
For the best lapping results, lightly tap the valve 
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve 
face and repeat the above steps.
f. After every lapping procedure, be sure to 
clean off all of the lapping compound from the 
valve face and valve seat.
g. Apply Mechanic ’s blueing dye (Dykem)  “b” 
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and  onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c”  again. If the 
valve seat width is out of specification, reface 
and lap the valve seat.
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haha VALVES AND VALVE SPRINGS
5-33
EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the 
valve springs.
1. Measure: Valve spring free length  “a”
Out of specification   Replace the valve 
spring.
2. Measure: Compressed valve spring force  “a”
Out of specification   Replace the valve 
spring. 3. Measure:
Valve spring tilt  “a”
Out of specification   Replace the valve 
spring.
EAS24320
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the 
valve lifters.
1. Check: Valve lifter
Damage/scratches   Replace the valve lift-
ers and cylinder head.
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the 
valves and related components.
1. Deburr: Valve stem end
(with an oil stone)
  Free length (intake)
40.22 mm (1.58 in)
Limit 38.21 mm (1.50 in)
Free length (exhaust) 40.22 mm (1.58 in)
Limit 38.21 mm (1.50 in)
  Installed compression spring 
force (intake)
192.00– 220.00 N (19.58– 22.43 
kgf, 43.16 –49.46 lbf)
Installed compression spring 
force (exhaust) 192.00– 220.00 N (19.58– 22.43 
kgf, 43.16 –49.46 lbf)
Installed length (intake) 32.00 mm (1.26 in)
Installed length (exhaust) 32.00 mm (1.26 in)
b. Installed length
  Spring tilt (intake)
2.5° /1.8 mm (2.5 °/0.07 in)
Spring tilt (exhaust) 2.5° /1.8 mm (2.5 °/0.07 in)     
						

							
haha VALVES AND VALVE SPRINGS
5-34
2. Lubricate: Valve stem “1”
 Valve stem end
 Valve stem seal  “2”
(with the recommended lubricant)
3. Install: Valve spring seat “1”
(into the cylinder head)
 Valve stem seal  “2” 
 Valve  “3”
 Valve spring “4”
 Valve spring retainer “5”
TIP
Make sure each valve is installed in its original 
place.
 Install the valve springs with the larger pitch  “a” 
facing up. 4. Install:
Valve cotters
TIP
Install the valve cotters by compressing the 
valve spring with the valve spring compressor 
“1”  and the valve spring compressor attachment 
“2”.
5. To secure the valve cotters onto the valve  stem, lightly tap the valve tip with a soft-face 
hammer.
NOTICE
ECA13800
Hitting the valve tip with excessive force 
could damage the valve.
  Recommended lubricant
Molybdenum disulfide oil
M
M
2
1
New
31 4 5
2New b. Smaller pitch
 
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attach-
ment 90890-01243
Valve spring compressor adapt-
er (26 mm) YM-01253-1      
						

							
haha VALVES AND VALVE SPRINGS
5-35
6. Lubricate: Valve pad
(with the recommended lubricant)
 Valve lifter
(with the recommended lubricant)
7. Install: Valve pad
 Valve lifter
TIP
The valve lifter must move smoothly when ro-
tated with a finger.
 Each valve lifter and valve pad must be rein-
stalled in their original position.
  Recommended lubricant
Molybdenum disulfide oil
  Recommended lubricant
Engine oil