2012 Na Yamaha Super Tenere Manual

							
haha TRANSMISSION
5-106
Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks
Middle drive pinion gear assembly Refer to “MIDDLE GEAR ” on page 5-112.
1 Bearing 1
2Washer 1
3 1st wheel gear 1
4Collar 1
5 5th wheel gear 1
6 Circlip 1
7 Toothed washer 1
8 3rd wheel gear 1
9 Toothed spacer 1
10 Toothed lock washer 1
11 Toothed lock washer retainer 1
New
M
E
1
62
7
8
9
10
11
3
4
5
M
M
M
M
M
M  
						

							
haha TRANSMISSION
5-107
Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks
12 4th wheel gear 1
13 Collar 1
14 Toothed washer 1
15 Circlip 1
16 6th wheel gear 1
17 Circlip 1
18 Toothed washer 1
19 2nd wheel gear 1
20 Collar 1
21 Drive axle 1
For assembly, reverse the disassembly pro-
cedure.
New
New
M
E
12
13
19
20
21
1415
16
18
17
M
M
M
M
M
M  
						

							
haha TRANSMISSION
5-108
EAS26250
REMOVING THE TRANSMISSION
1. Remove: Main axle assembly  “1”
TIP
Remove the main axle assembly with the slide 
hammer bolts “2” and weight.
EAS26260
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift 
forks.
1. Check: Shift fork cam follower  “1”
 Shift fork pawl  “2”
Bends/damage/scoring/wear   Replace the 
shift fork.
2. Check: Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends   Replace.
WARNING
EWA12840
Do not attempt to straighten a bent shift fork 
guide bar. 3. Check:
Shift fork movement
(along the shift fork guide bar)
Rough movement   Replace the shift forks 
and shift fork guide bar as a set.
4. Check: Springs
Cracks/damage   Replace.
EAS26270
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check: Shift drum groove
Damage/scratches/wear   Replace the shift 
drum assembly.
 Shift drum segment  “1”
Damage/wear   Replace the shift drum as-
sembly.
 Shift drum bearing “2”
Damage/pitting   Replace the shift drum as-
sembly.
EAS26300
CHECKING THE TRANSMISSION
1. Measure: Main axle runout
(with a centering device and dial gauge  “1”)
 Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm YU-01083-1
Weight 90890-01084
YU-01083-3
2
2 1
1
2     
						

							
haha TRANSMISSION
5-109
Out of specification   Replace the main axle.
2. Measure: Drive axle runout
(with a centering device and dial gauge  “1”)
Out of specification   Replace the drive axle.
3. Check: Transmission gears
Blue discoloration/pitting/wear   Replace 
the defective gear(s).
 Transmission gear dogs
Cracks/damage/rounded edges   Replace 
the defective gear(s).
4. Check: Transmission gear engagement
(each pinion gear to its respective wheel 
gear) Incorrect 
 Reassemble the transmission 
axle assemblies.
5. Check:
Transmission gear movement
Rough movement   Replace the defective 
part(s).
EAS23P1046
ASSEMBLING THE MAIN AXLE AND DRIVE 
AXLE
1. Install: Circlip  “1” 
TIP
Install the circlip so that a spline “a”  is in the cen-
ter of the gap between the circlip ends  “b” as 
shown.
2. Install:
Toothed lock washer retainer “1”
 Toothed lock washer “2”
TIP
With the toothed lock washer retainer in the 
groove  “a” in the axle, align the projection on 
the retainer with an axle spline, and then install 
the toothed lock washer.
 Be sure to align the projection on the toothed 
lock washer that is between the alignment 
marks  “b” with the alignment mark  “c” on the re-
tainer.
  Main axle runout limit
0.08 mm (0.0032 in)
  Drive axle runout limit
0.08 mm (0.0032 in)
1
1
New
New
a
1 b   
						

							
haha TRANSMISSION
5-110
3. Install: Bearing “1”
TIP
Be sure to install the bearing so that the seal  “2” 
is facing outward.
EAS26350
INSTALLING THE TRANSMISSION
1. Install:
Bearing “1”
TIP
Face the seal side of the bearing to the outside 
and install it close to the left side end of the up-
per crankcase. 2. Install:
Main axle assembly  “1”
 Main axle bearing housing bolts
TIP
When installing the main axle assembly, use a 
pin  “2” to align the bearing housing hole with the 
corresponding hole in the upper crankcase. 
3. Install:
Shift drum assembly
 Shift fork-C
 Shift fork upper guide bar
 Shift fork-R
 Shift fork-L
 Springs
 Shift fork lower guide bar
TIP
The embossed marks on the shift forks should 
face towards the right side of the engine and be 
in the following sequence:  “R”, “C” , “L”.
4. Install: Shift drum upper retainer  “1”
 Shift drum lower retainer  “2”
A. Main axle
B. Drive axle
2
1
c
b
b
1
2
a
A
2
b
b
1c
1
2
a
B
1 2
T R..  Main axle bearing housing bolt
12 Nm (1.2 m ·kgf, 8.7 ft· lbf)
LOCTITE ®
T R..  Shift drum retainer screw
10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
LOCTITE ®
1
2
1  
						

							
haha TRANSMISSION
5-111
TIP
 Install each shift drum retainer with its  “OUT” 
mark  “a” facing outward.
 Align the projection  “b” on the shift fork upper 
guide bar with the slot  “c” in the shift drum up-
per retainer.
5. Check: Transmission
Rough movement   Repair.
TIP
Oil each gear, shaft, and bearing thoroughly.
b
c
a
2 1  
						

							
haha MIDDLE GEAR
5-112
EAS25711
MIDDLE GEAR Removing the middle driven pinion gear
Order Job/Parts to remove Q ’ty Remarks
Engine Refer to “ENGINE REMOVAL ” on page 5-3.
1 Middle gear side cover 1
2 Middle gear side cover gasket 1
3 Dowel pin 2
4 Middle gear side cover damper plate 1
5 Middle gear side cover damper 1
6 Circlip 4
7 Bearing 4
8 Universal joint 1
9 Middle driven pinion gear assembly 1
10 Middle driven pinion gear shim Refer to 
“ADJUSTING THE MIDDLE GEAR 
BACKLASH ” on page 5-120 and  “ALIGNING 
THE MIDDLE GEAR ” on page 5-122.
10 8
106
9
7
7
7
7 66
6
12
(6) 3
3
4
5
(4)
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.LTLT
33 Nm (3.3 m 
kgf, 24 ft 
Ibf)T.R.
LT
E
LS
LS
LS
LT
LT
LS
LS
LS
LS
LS
New
New
E
E
FWD  
						

							
haha MIDDLE GEAR
5-113
Removing the middle driven pinion gear Order Job/Parts to remove Q ’ty Remarks
11 Universal joint yoke nut 1
12 Washer 1
13 Universal joint yoke 1
14 Middle driven pinion gear 1
15 Expander 1
16 Bearing 1
17 Oil seal 1
18 Bearing 1
19 Bearing race 2
20 Middle driven pinion gear bearing housing 1
For installation, reverse the removal proce-
dure.
14 12
13
11
16
19
181920
17
(6)
(4)
15
10 Nm (1.0 m

kgf, 7.2 ft 
Ibf)T.R.
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.LTLT
33 Nm (3.3 m 
kgf, 24 ft 
Ibf)T.R.
LT
E
LS
LS
LS
LT
LT
LS
LS
LS
LS
LS
New
New
New
New
E
E
FWD  
						

							
haha MIDDLE GEAR
5-114
Removing the middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks
Crankcase Separate.
Refer to 
“CRANKCASE ” on page 5-81.
1 Middle drive pinion gear bearing retainer 1
2 Middle drive pinion gear shim Refer to 
“ALIGNING THE MIDDLE GEAR ” 
on page 5-122.
3 Drive axle/middle drive pinion gear assembly 1
4 Spring retainer 2
5Washer 1
6 Middle drive pinion gear assembly 1
7 Torque damper cam 1
8Spring 1
9 Spring seat 1
10 Bearing 1
E
LT
FWD
E
M
M
7
8
9
10 5
4 1
(4)
6
3
2
28 Nm (2.8 m 
kgf, 20 ft 
Ibf)T.R.
110 Nm (11 m 
kgf, 80 ft 
lbf)T.R.  
						

							
haha MIDDLE GEAR
5-115
Removing the middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks
11 Middle drive pinion gear nut 1
12 Middle drive pinion gear 1
13 Bearing 1
14 Middle drive pinion gear bearing housing 1
For installation, reverse the removal proce-
dure.
E
LT
FWD
E
M
M
New11
12
14
13
(4)
28 Nm (2.8 m
kgf, 20 ft 
Ibf)T.R.
110 Nm (11 m 
kgf, 80 ft 
lbf)T.R.