2012 Na Yamaha Super Tenere Manual
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haha MIDDLE GEAR 5-116 EAS23P1033 REMOVING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Remove: Universal joint ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Remove the circlips “1”. b. Place the universal joint in a press. c. With a pipe “2” of the proper diameter posi- tioned beneath the universal joint yoke “3” as shown, press out the bearings “4”. TIP It may be necessary to lightly tap the universal joint yoke. d. Repeat the above steps to remove the oppo- site side ’s bearing. e. Separate the universal joint yokes. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ ECA23P1047 DISASSEMBLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Remove: Universal joint yoke nut “1” TIP Straighten the collar on the universal joint yoke nut. Wrap the middle driven pinion gear bearing housing in a folded rag, and then secure it in a vise. While holding the universal joint yoke “2” with the universal joint holder “3” and the 20 mm (0.79 in) diameter attachment, loosen the uni- versal joint yoke nut. Place a rag between the attachment and the universal joint yoke as shown in the illustration. EAS23P1035 REMOVING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Remove: Spring retainers “1” Washer TIP While compressing the spring with the damper spring compressor “2”, remove the spring retain- ers and washer. EAS23P1036 DISASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Remove: Middle drive pinion gear nut ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Straighten the collar on the middle drive pin- ion gear nut. 1 3 2 4 1 1 4 Universal joint holder 90890-04160 YM-04062 Damper spring compressor 90890-04090 Middle drive gear damper spring compressor YM-33286 3 2 1 2 1
haha MIDDLE GEAR 5-117 b. Attach the middle drive shaft nut wrench (55 mm) “1”. TIP Wrap the middle drive pinion gear in a folded rag, and then secure it in a vise. c. Loosen the middle drive pinion gear nut. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS23P1037 CHECKING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Check: Middle driven pinion gear Galling/pitting/wear Replace the middle driven pinion gear and middle drive pinion gear as a set. 2. Check: Bearings Damage/pitting Replace. 3. Check: Universal joint movement Rough movement Replace the universal joint. EAS23P1038 CHECKING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Check: Middle drive pinion gear Galling/pitting/wear Replace the middle drive pinion gear and middle driven pinion gear as a set. 2. Check: Torque damper cam surface Scratches/wear Replace. 3. Check: Spring Cracks/damage Replace. 4. Check: Bearings Damage/pitting Replace. EAS23P1039 ASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Install: Middle drive pinion gear nut ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Attach the middle drive shaft nut wrench (55 mm) “1”. TIP Wrap the middle drive pinion gear in a folded rag, and then secure it in a vise. b. Tighten the middle drive pinion gear nut to specification. c. Lock the threads with a drift punch. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ Middle drive shaft nut wrench (55 mm) 90890-04054 Offset wrench 55 mm YM-04054 1 Middle drive shaft nut wrench (55 mm) 90890-04054 Offset wrench 55 mm YM-04054 T R.. Middle drive pinion gear nut 110 Nm (11.0 m ·kgf, 80 ft· lbf) New 1
haha MIDDLE GEAR 5-118 EAS23P1040 INSTALLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Install: Washer Spring retainers “1” TIP While compressing the spring with the damper spring compressor “2”, install the washer and spring retainers. EAS23P1041 ASSEMBLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Install: Oil seal “1” (to the middle driven pinion gear bearing housing) 2. Install: Washer “1” TIP Install the washer with its “OUT” mark “a” facing outward. 3. Install: Universal joint yoke nut “1” ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Tighten the universal joint yoke nut. (temporarily) TIP Apply LOCTITE ® to the universal joint yoke nut. Wrap the middle driven pinion gear bearing housing in a folded rag, and then secure it in a vise. While holding the universal joint yoke “2” with the universal joint holder “3” and the 20 mm (0.79 in) diameter attachment, tighten the uni- versal joint yoke nut. Place a rag between the attachment and the universal joint yoke as shown in the illustration. After tightening the nut, check the operation of the middle driven pinion gear assembly. If there is looseness in the assembly, disassem- ble it and check if the bearings are installed properly. When reassembling the middle driven pinion gear assembly, replace the expander with a new one. Damper spring compressor 90890-04090 Middle drive gear damper spring compressor YM-33286 Installed depth “a” -0.5 –0.5 mm (-0.02 –0.02 in) 2 1 1 a T R.. Universal joint yoke nut (tempo- rarily) 140– 230 Nm (14 –23 m· kgf, 100 – 166 ft· lbf) LOCTITE ® Universal joint holder 90890-04160 YM-04062 1 a New
haha MIDDLE GEAR 5-119 b. Remove the universal joint holder, and then turn the nut with a torque wrench to check the starting torque. c. Out of specification Tighten the nut further. d. Repeat steps (a) to (c) until the starting torque is within specification. TIP Be careful not to exceed the specified starting torque. If the specified starting torque is exceeded, re- place the expander with a new one and reas- semble the middle driven pinion gear assembly. e. Lock the threads with a drift punch. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 4. Check: Middle driven pinion gear operation Rough operation Replace the middle driv- en pinion gear assembly. 5. Check: Middle gear backlash Out of specification Adjust the backlash. EAS23P1042 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Install: Middle driven pinion gear shim(s) “1” Middle driven pinion gear assembly TIP Install the shim(s) so that the tabs are positioned as shown in the illustration. 2. Install: Universal joint ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Fit the universal joint into the yoke. b. Apply lithium-soap-based grease to the bear- ings. c. Install the bearing “1” into the yoke. NOTICE ECA23P1046 Check each bearing. The needle bearings can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place. T R.. Middle driven pinion gear start- ing torque (middle driven pinion gear preload) 0.3– 0.6 Nm (0.03– 0.06 m·kgf, 0.022 –0.43 ft· lbf) 3 2 1 NewT R.. Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m ·kgf, 24 ft· lbf) LOCTITE ® 1
haha MIDDLE GEAR 5-120 d. Press each bearing into the yoke using a suit- able socket. TIP The bearing must be inserted far enough into the yoke so that the circlip can be installed. e. Install the circlips “2” into the groove of each bearing. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 3. Check: Universal joint operation Rough operation Replace the universal joint or bearing. TIP Lift the universal joint “1” and make sure that it falls freely when released. EAS25880 MEASURING THE MIDDLE GEAR BACKLASH 1. Remove: Universal joint Middle gear side cover 2. Measure: Middle gear backlash Out of specification Refer to “ ADJUSTING THE MIDDLE GEAR BACKLASH ” on page 5-120. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Hold the middle drive pinion gear “1” with the middle gear backlash tool “2”. TIP Finger tighten the middle gear backlash tool bolts. b. Make sure the dial gauge plunger contacts the measuring point on the centerline of the yoke bearing hole as shown. c. While gently turning the universal joint yoke back and forth, measure the middle gear backlash. TIP Measure the middle gear backlash at four posi- tions. Rotate the universal joint yoke 90° each time and observe the reading on the dial gauge. ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS25900 ADJUSTING THE MIDDLE GEAR BACKLASH 1. Loosen: Middle driven pinion gear bearing housing bolts 2. Remove: Middle driven pinion gear shim(s) 3. Tighten: Middle driven pinion gear bearing housing bolts 1 2 1 Middle gear backlash 0.045 –0.090 mm (0.002– 0.004 in) Middle gear backlash tool 90890-04080 Middle drive gear holder YM-33222 1 2
haha MIDDLE GEAR 5-121 NOTICE ECA23P1047 Do not overtighten the middle driven pinion gear bearing housing bolts or you may ob- tain too little middle gear backlash and dam- age the middle gears. If the bolts are overtightened, loosen them until the crank- case-to-middle-driven-pinion gear-bearing- housing clearance is within specification, as stated below. Then, repeat all of the previous steps. TIP Tighten the middle driven pinion gear bearing housing bolts carefully, one thread turn at a time only. Push in the middle driven pinion gear bearing housing and then tighten the bolts to specification. Clearance between the crankcase and the middle driven pinion gear bearing housing should be approximately 2 mm (0.08 in), when measured with a thickness gauge “1”. 4. Hold the middle drive pinion gear. 5. Turn: Universal joint yoke TIP While carefully tightening the middle driven pin- ion gear bearing housing bolts in stages and in a crisscross pattern, turn the universal joint yoke back and forth until the dial gauge reads 0.045– 0.090 mm (0.002– 0.004 in). 6. Measure: Crankcase-to-middle-driven-pinion gear- bearing-housing clearance (with a thickness gauge) 7. Select: Middle driven pinion gear shim(s) “1” ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Shims are only available in 0.05 mm incre- ments, therefore round off to the hundredth ’s digit of the calculated thickness and select the appropriate shim(s) with the following chart. b. For example, the clearance between the crankcase and the middle driven pinion gear bearing housing is 0.46 mm. Therefore, the chart instructs you to round off the 6 to 5. Thus, you should use one 0.15 mm and one 0.30 mm shim. Shims are supplied in the following thickness- es. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 8. Loosen: Middle driven pinion gear bearing housing bolts 9. Install: Middle driven pinion gear shim(s) Refer to “ INSTALLING THE MIDDLE DRIV- EN PINION GEAR ASSEMBLY” on page 5-119. 10.Tighten: Middle driven pinion gear bearing housing bolts T R.. Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m· kgf, 24 ft·lbf) 1 Hundredth Rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 Middle driven pinion gear shim Thickness (mm)0.10 0.15 0.20 0.30 0.40 0.50 T R.. Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m ·kgf, 24 ft· lbf) LOCTITE ® 1
haha MIDDLE GEAR 5-122 11.Measure: Middle gear backlash Out of specification Refer to “MEASUR- ING THE MIDDLE GEAR BACKLASH ” on page 5-120. EAS25930 ALIGNING THE MIDDLE GEAR TIP Aligning the middle gear is necessary when any of the following parts are replaced: Crankcase Middle drive pinion gear Middle driven pinion gear Middle driven pinion gear bearing housing 1. Select: Middle drive pinion gear shim(s) “1” Middle driven pinion gear shim(s) “2” TIP Select the middle driven pinion gear shim(s) “2” by calculating the middle drive pinion gear shim thickness and then measuring the middle gear backlash. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Position the middle gears with the appropri- ate shim(s) that has had its respective thick- ness calculated from information marked on the upper crankcase, middle driven pinion gear, and bearing housings. b. To find middle drive pinion gear shim thick- ness “A”, use the following formula. “a” = a numeral on the middle drive pinion gear bearing housing, to be divided by 100 and added to “14.00” “b” = 52.20 “c” = a numeral on the upper crankcase, to be divided by 100 and added to “66.00” Example: If the middle drive pinion gear bearing hous- ing is marked “57” “a” is 14.57 (i.e., 14.00 + 0.57 = 14.57) “b” is 52.20 If the upper crankcase is marked “18” “c” is 66.18 (i.e., 66.00 + 0.18 = 66.18) “A” = 14.57 + 52.20 - 66.18 - 0.1 = 0.49 Round off to the hundredths digit and select the appropriate shim(s). TIP In the above example, the calculated number is 0.49. The chart instructs you to round off the 9 to 10. Thus, the shim thickness is 0.50 mm. A. Middle drive pinion gear shim thickness B. Middle driven pinion gear shim thickness ba A c g f d e B 1 2 Middle drive pinion gear shim thickness “A” = “a” + “b” - “c” - 0.1 Hundredths Rounded value0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 a c
haha MIDDLE GEAR 5-123 Shims are supplied in the following thickness- es. c. To find middle driven pinion gear shim thick- ness “B”, use the following formula. “d” = a numeral on the middle driven pinion gear bearing housing, to be divided by 100 and either added to or subtracted from “ 55.95” “e” = a numeral on the middle driven pinion gear, to be divided by 100 and either added to or subtracted from “13.40” “f” = a numeral on the middle driven pinion gear, to be divided by 100 and either added to or subtracted from “57.00” “g” = a numeral on the upper crankcase, to be divided by 100 and added to “98.00” TIP If the upper crankcase is marked “00” , “g” is 99.00. Example: If the middle driven pinion gear bearing hous- ing is marked “+17” “d” is 56.12 (i.e., 55.95 + 0.17 = 56.12) If the middle driven pinion gear is marked “ +03” “e” is 13.43 (i.e., 13.40 + 0.03 = 13.43) If the middle driven pinion gear is marked “- 02” “f” is 56.98 (i.e., 57.00 - 0.02 = 56.98) If the upper crankcase is marked “93” “g” is 98.93 (i.e., 98.00 + 0.93 = 98.93) TIP If the upper crankcase is marked “00” , “g” is 99.00. “B” = 56.12 - 13.43 + 56.98 - 98.93 = 0.74 Round off to the hundredths digit and select the appropriate shim(s). TIP In the above example, the calculated number is 0.74. The chart instructs you to round off the 4 to 5. Thus, the shim thickness is 0.75 mm. Shims are supplied in the following thickness- es. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ Middle drive pinion gear shim Thickness (mm)0.10 0.15 0.20 0.30 0.40 0.50 Middle driven pinion gear shim thickness “B” = “d” - “e” + “f ” - “g” d e f Hundredths Rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 Middle driven pinion gear shim Thickness (mm)0.10 0.15 0.20 0.30 0.40 0.50 g
haha 6 COOLING SYSTEM RADIATOR ...................................................................................................... 6-1 CHECKING THE RADIATOR .................................................................... 6-3 INSTALLING THE RADIATOR .................................................................. 6-3 THERMOSTAT ................................................................................................ 6-4 CHECKING THE THERMOSTAT.............................................................. 6-5 INSTALLING THE THERMOSTAT............................................................ 6-5 WATER PUMP ................................................................................................. 6-6 DISASSEMBLING THE WATER PUMP.................................................... 6-8 CHECKING THE WATER PUMP .............................................................. 6-8 ASSEMBLING THE WATER PUMP.......................................................... 6-8 INSTALLING THE WATER PUMP .......................................................... 6-10
haha RADIATOR 6-1 EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q ’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT ” on page 3-27. Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. 1 Coolant reservoir hose 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir 1 5 Water pump inlet hose 1 6 Radiator outlet hose 1 7 Radiator outlet pipe 1 2 3 4 1 657 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R. 2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R.2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R. 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)T.R. 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)T.R.