2012 Na Yamaha Super Tenere Manual

							
haha CRANKCASE
5-86
EAS23P1092
REMOVING THE REAR BALANCER
1. Remove: Rear balancer  “1”
NOTICE
ECA23P1075
The rear balancer should not be disassem-
bled.
EAS25550
DISASSEMBLING THE CRANKCASE
1. Remove:
Oil filter cartridge  “1”
TIP
Remove the oil filter cartridge with an oil filter 
wrench “2”.
2. Remove: Crankcase bolts
 O-rings
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the 
bolts are fully loosened, remove them.
 Loosen the bolts in decreasing numerical order 
(refer to the numbers in the illustration).
 The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M10 ×  130 mm bolts:  “1”–“6”
 M8  × 78 mm bolts:  “7”–“12” 
M8  × 80 mm bolts:  “13”–“19”
 M8  × 60 mm bolts:  “20” , “21” , “30”–“32”
 M6  × 50 mm bolts:  “22” , “24”–“ 27”, “ 29”
 M6  × 65 mm bolts:  “23” , “28”
3. Remove: Upper crankcase
  Oil filter wrench
90890-01426
YU-38411
1
2
1
A. Lower crankcase
B. Upper crankcase
×2×6
×6×7
×2
×69
3
2
10
4 6
11
12
7
8
1
13
15
16
17 18
19
20
21
22
2425
26
27
28
29
14
5
23
A
×3
3130
32
B  
						

							
haha CRANKCASE
5-87
NOTICE
ECA13900
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase 
mating surfaces. Work slowly and carefully 
and make sure the crankcase halves sepa-
rate evenly.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a  mild solvent.
2. Thoroughly clean all the gasket surfaces and  crankcase mating surfaces.
3. Check:
Crankcase
Cracks/damage   Replace.
 Oil delivery passages
Obstruction   Blow out with compressed air.
EAS23P1032
CHECKING THE REAR BALANCER
1. Check: Rear balancer
 Rear balancer shaft
Damage/wear   Replace the rear balancer 
and rear balancer shaft as a set.
Dirt   Clean.
EAS23P1044
CHECKING THE TIMING CHAIN AND TIMING 
CHAIN GUIDE (INTAKE SIDE)
1. Check: Timing chain
Damage/stiffness   Replace the timing 
chain, camshaft sprockets, and crankshaft as 
a set.
 Timing chain guide (intake side)
Damage/wear   Replace.
EAS23P1094
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil 
nozzles.
1. Check: Oil nozzle
Damage/wear   Replace.
 Oil passage
Obstruction   Blow out with compressed air.
EAS25680
ASSEMBLING THE CRANKCASE
1. Lubricate: Crankshaft journal bearings
(with the recommended lubricant) 
Front balancer shaft journal bearings
(with the recommended lubricant)
2. Apply: Sealant
(onto the crankcase mating surfaces)
NOTICE
ECA23P1043
Do not allow any sealant to come into con-
tact with the oil gallery, crankshaft journal 
bearings, or front balancer shaft journal 
bearings.
3. Install:
Dowel pins
4. Set the shift drum assembly and transmission  gears in the neutral position.
5. Check:
Alignment of punch mark “a”  in the front bal-
ancer shaft and punch mark  “b” in the crank-
shaft
Out of alignment   Adjust.
Refer to “ INSTALLING THE FRONT BAL-
ANCER SHAFT ” on page 5-101.
  Recommended lubricant
Engine oil
  Yamaha bond No. 1215
90890-85505
(Three Bond No.1215 ®)  
						

							
haha CRANKCASE
5-88
6. Align: Match mark  “a” in the front balancer shaft
(with the crankcase mating surface  “b”)
7. Install: Upper crankcase  “1”
(onto the lower crankcase  “2”)
NOTICE
ECA23P1044
Before tightening the crankcase bolts, 
make sure the transmission gears shift cor-
rectly when the shift drum assembly is 
turned by hand.
 Make sure that the punch mark in the crank-
shaft remains aligned with the punch mark 
in the front balancer gear.
8. Install: O-rings 
 Crankcase bolts
WARNING
EWA23P1015
Replace the bolts  “1”–“ 6” with new ones.
TIP
Before installing the crankcase bolts “7 ”–“12” , 
install the O-rings onto the bolts, making sure 
that each O-ring contacts the bolt flange.
 Lubricate the bolts  “1”–“6”  threads and wash-
ers with engine oil.
 Lubricate the bolts “7 ”–“32” threads and mating 
surfaces with engine oil.
 Finger tighten the crankcase bolts.
M10 ×  130 mm bolts:  “1”–“6” 
 M8  × 78 mm bolts:  “7”–“12”
 M8  × 80 mm bolts:  “13”–“19”
 M8  × 60 mm bolts:  “20” , “21” , “30”–“32”
 M6  × 50 mm bolts:  “22” , “24”–“ 27”, “ 29”
 M6  × 65 mm bolts:  “23” , “28”
a b
ab
2 1
New
New
×2×6
×6×7
×2
×69
3
2
10
4 6
11
12
7
8
1
13
15
16
17 18
19
20
21
22
2425
26
27
28
29
14
5
23
A  
						

							
haha CRANKCASE
5-89
9. Tighten: Crankcase bolts (M10  × 130 mm) “1 ”–“6”
TIP
The tightening procedure of crankcase bolts  “1”–  
“6”  is angle controlled; therefore, tighten the 
bolts using the following procedure.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Tighten the crankcase bolts in the proper 
tightening sequence as shown.
b. Tighten the crankcase bolts in the proper  tightening sequence as shown.
c. Tighten the crankcase bolts further to reach  the specified angle 90 –100°.
WARNING
EWA23P1016
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new 
one and perform the procedure again.
NOTICE
ECA23P1045
 Do not use a torque wrench to tighten the 
bolt to the specified angle.
 Tighten the bolt until it is at the specified 
angle.
TIP
On a hexagonal bolt, note that the angle from 
one corner to another is 60 °.
▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
10.Tighten: Crankcase bolts “7 ”–“32”
A. Lower crankcase
B. Upper crankcase
T R.. 
Crankcase bolt “1
”–“6”
1st 10 Nm (1.0 m· kgf, 7.2 ft·lbf)
T R..  Crankcase bolt “1
”–“6”
2nd 20 Nm (2.0 m· kgf, 14 ft·lbf)
T R.. Crankcase bolt “1
”–“6”
Final Specified angle 90 –100°
×3
3130 32
B
1
2
5
4 6
3
90-100
30 30   
						

							
haha CRANKCASE
5-90
TIP
Tighten the crankcase bolts in the proper tight-
ening sequence as shown. 11.Install:Middle drive pinion gear bearing retainer  “1”
TIP
Install the middle drive pinion gear bearing re-
tainer with its arrow mark “a” facing up.
12.Install: Oil delivery passage cover  “1”
T R.. Crankcase bolt “7
”–“21”, “30 ”–
“ 32 ”
24 Nm (2.4 m· kgf, 17 ft·lbf)
Crankcase bolt “ 22”–“29”
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
11
13
16
17 18
19
20
21
26
27
28
29
A
9
12
7
8
1522
24
25
14
10
23
A. Lower crankcase
B. Upper crankcase
T R..  Middle drive pinion gear bearing 
retainer bolt
28 Nm (2.8 m ·kgf, 20 ft· lbf)
LOCTITE ®
T R..  Oil delivery passage cover
12 Nm (1.2 m ·kgf, 8.7 ft· lbf)
LOCTITE ®
31 3230
B
1
a  
						

							
haha CRANKCASE
5-91
TIP
Apply Three Bond No.1541C ® “2” onto the mat-
ing surfaces of the oil delivery passage cover 
and oil delivery passage cover O-ring.
EAS23P1095
INSTALLING THE REAR BALANCER
1. Install: Rear balancer
 Rear balancer shaft
 Rear balancer shaft retainer
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Check that the match mark  “a” in the front bal-
ancer shaft is aligned with the crankcase 
mating surface  “b”.
b. Align the punch mark  “c” in the rear balancer 
with the match mark “d”  on the upper crank-
case.
c. Install the rear balancer shaft, and then tight- en the bolt to specification.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
1 2
a
b
c
d
T R.. Rear balancer shaft retainer bolt
12 Nm (1.2 m ·kgf, 8.7 ft· lbf)
LOCTITE ®  
						

							
haha CRANKSHAFT AND BALANCER
5-92
EAS25950
CRANKSHAFT AND BALANCER Removing the crankshaft, connecting rods and front balancer
Order Job/Parts to remove Q ’ty Remarks
Crankcase Separate.
Refer to 
“CRANKCASE ” on page 5-81.
1 Front balancer shaft 1
NOTICE
ECA23P1076
The front balancer shaft should not be 
disassembled.
2 Front balancer shaft journal lower bearing 3
3 Front balancer shaft journal upper bearing 3
4 Crankshaft 1
5 Crankshaft journal lower bearing 3
6 Crankshaft journal upper bearing 3
7 Connecting rod cap 2
M
M
M
M
FWD
E
E
E
E
E
E
E
E
New
New
New
1
3
3
3
2 2
2
6
6
45
7
1st 20 Nm (2.0 m 
kgf, 14 ft 
Ibf)
2nd Specified angle 145–155T.R.  
						

							
haha CRANKSHAFT AND BALANCER
5-93
Removing the crankshaft, connecting rods and front balancer Order Job/Parts to remove Q ’ty Remarks
8 Big end lower bearing 2
9 Connecting rod 2
10 Big end upper bearing 2
For installation, reverse the removal proce-
dure.
M
M
M
M
FWD
E
E
E
E
E
E
E
E
New
New
New
910
8
1st 20 Nm (2.0 m 
kgf, 14 ft 
Ibf)
2nd Specified angle 145–155T.R.  
						

							
haha CRANKSHAFT AND BALANCER
5-94
EAS23P1096
REMOVING THE FRONT BALANCER SHAFT
1. Remove: Front balancer shaft  “1”
NOTICE
ECA23P1076
The front balancer shaft should not be disas-
sembled.
EAS23P1043
REMOVING THE BALANCER SHAFT 
JOURNAL BEARINGS
1. Remove:
Front balancer shaft journal lower bearings
(from the lower crankcase)
 Front balancer shaft journal upper bearings
(from the upper crankcase)
TIP
Identify the position of each front balancer shaft 
journal bearing so that it can be reinstalled in its 
original place.
EAS26040
REMOVING THE CRANKSHAFT JOURNAL 
BEARINGS
1. Remove:
Crankshaft journal lower bearings
(from the lower crankcase)
 Crankshaft journal upper bearings
(from the upper crankcase)
TIP
Identify the position of each crankshaft journal 
bearing so that it can be reinstalled in its original 
place.
EAS26010
REMOVING THE CONNECTING RODS
The following procedure applies to all of the con-
necting rods.
1. Remove:
Connecting rod cap
 Connecting rod
 Big end bearings
TIP
Identify the position of each connecting rod cap, 
connecting rod, and big end bearing so that it 
can be reinstalled in its original place.
EAS26070
CHECKING THE CRANKSHAFT
1. Measure:
Crankshaft runout
Out of specification   Replace the crank-
shaft.
2. Check: Crankshaft journal surfaces
 Crankshaft pin surfaces
 Bearing surfaces
Scratches/wear   Replace the crankshaft.
3. Measure: Crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification   Replace the crank-
shaft journal bearings.
NOTICE
ECA13920
Do not interchange the crankshaft journal 
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in 
their original positions.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Clean the crankshaft journal bearings, crank-
shaft journals, and bearing portions of the 
crankcase.
1
  Runout limit C
0.020 mm (0.0008 in)
  Journal oil clearance
0.020 –0.044 mm (0.0008– 0.0017 
in)  
						

							
haha CRANKSHAFT AND BALANCER
5-95
b. Install the crankshaft journal lower bearings  “1” and the crankshaft into the lower crank-
case.
TIP
Align the projections “a”  on the crankshaft jour-
nal lower bearings with the notches  “b” in the 
lower crankcase.
c. Put a piece of Plastigauge ® “2” on each 
crankshaft journal.
TIP
Do not put the Plastigauge ® over the oil hole in 
the crankshaft journal.
d. Install the crankshaft journal upper bearings 
“3” into the upper crankcase and assemble 
the crankcase halves.
TIP
 Align the projections “d”  of the crankshaft jour-
nal upper bearings with the notches  “e” in the 
upper crankcase.
 Do not move the crankshaft until the clearance 
measurement has been completed. e. Tighten the bolts to specification in the tight-
ening sequence cast on the crankcase.
Refer to “ CRANKCASE”  on page 5-81.
f. Remove the upper crankcase and the crank-
shaft journal upper bearings.
g. Measure the compressed Plastigauge®  width  “g” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specification, 
select replacement crankshaft journal bear-
ings.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Select: Crankshaft journal bearings (J
1–J
3)
TIP

The numbers  “A” stamped into the lower crank-
case and the numbers  “B” stamped into the 
crankshaft web are used to determine the re-
placement crankshaft journal bearing sizes.
 J 1–J
3 refer to the bearings shown in the lower 
crankcase and crankshaft web illustration.
 If J
1–J
3 are the same, use the same size for all 
of the bearings.
c. Oil groove
c
1
a
b
2
f. Oil groove
3 d
e f
g