2012 Na Yamaha Super Tenere Manual
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haha 7 FUEL SYSTEM FUEL TANK ..................................................................................................... 7-1 REMOVING THE FUEL TANK .................................................................. 7-4 REMOVING THE FUEL PUMP ................................................................. 7-4 CHECKING THE FUEL PUMP BODY....................................................... 7-4 CHECKING THE ROLLOVER VALVES (for California only) .................... 7-4 INSTALLING THE FUEL PUMP ................................................................ 7-4 INSTALLING THE FUEL TANK................................................................. 7-5 THROTTLE BODIES ....................................................................................... 7-6 CHECKING THE INJECTORS (BEFORE REMOVING) ........................... 7-9 REMOVING THE INJECTORS ................................................................. 7-9 CHECKING THE INJECTORS .................................................................. 7-9 CHECKING AND CLEANING THE THROTTLE BODIES ......................... 7-9 CHECKING THE THROTTLE BODY JOINTS ........................................ 7-11 INSTALLING THE INJECTORS .............................................................. 7-11 CHECKING THE INJECTOR PRESSURE.............................................. 7-11 CHECKING THE FUEL PRESSURE ...................................................... 7-12 ADJUSTING THE THROTTLE POSITION SENSOR.............................. 7-13 ADJUSTING THE ACCELERATOR POSITION SENSOR...................... 7-13 INSTALLING THE THROTTLE BODY JOINTS ...................................... 7-14
haha FUEL TANK 7-1 EAS26620 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’tyRemarks Left side cowling/Right side cowling/Rider seat height position adjuster Refer to “GENERAL CHASSIS” on page 4-1. 1 Front fuel tank bolt 2 2 Fuel pump coupler 1 Disconnect. 3 Fuel sender coupler 1 Disconnect. 4 Fuel hose holder 1 5 Fuel hose 1 6 Fuel tank overflow hose 1 Disconnect. 7 Fuel tank breather hose (fuel tank to rollover valve) 1 Disconnect. 8Fuel tank 1 9 Fuel pump 1 10 Rear fuel tank bracket 1 New 1 2 6 7 3 5 4 9(4) (6) 8 10 1 10 Nm (1.0 m • kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 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. 16 Nm (1.6 m kgf, 12 ft Ibf)T.R. 4.0 Nm (0.40 m kgf, 2.9 ft Ibf)T.R.
haha FUEL TANK 7-2 Removing the fuel tank and fuel pump Order Job/Parts to remove Q ’ty Remarks 11 Seat lock assembly 1 12 Seat lock cable 1 Disconnect. For installation, reverse the removal proce- dure. New (4) (6) 11 12 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 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. 16 Nm (1.6 m kgf, 12 ft Ibf)T.R. 4.0 Nm (0.40 m kgf, 2.9 ft Ibf)T.R.
haha FUEL TANK 7-3 Removing the canister (for California only) Order Job/Parts to remove Q ’ty Remarks Fuel tank Refer to “FUEL TANK ” on page 7-1. 1 Fuel tank overflow hose 1 2 Fuel tank breather hose (fuel tank to rollover valve) 1 3 Rollover valve 1 4 Fuel tank breather hose (rollover valve to canis- ter) 1 5 Canister purge hose (hose joint to canister) 1 6 Canister breather hose 1 7 Canister 1 8 Canister bracket 1 For installation, reverse the removal proce- dure. 7 3 8 2 1 5 4 6 FWD 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.
haha FUEL TANK 7-4 EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: Fuel hose WARNING EWA23P1001 Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose. NOTICE ECA23P1090 Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it. TIP To remove the fuel hose from the fuel rail, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown, press the two buttons “2” on the sides of the connector, and then remove the hose. Remove the fuel hose manually without using any tools. Before removing the hose, place a few rags in the area under where it will be removed. 3. Remove: Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump. Be sure to lean the fuel tank against a wall or the like. EAS26640 REMOVING THE FUEL PUMP 1. Remove: Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender. EAS26670 CHECKING THE FUEL PUMP BODY 1. Check: Fuel pump body Obstruction Clean. Cracks/damage Replace fuel pump as- sembly. EAS23P4002 CHECKING THE ROLLOVER VALVES (for California only) 1. Check: Rollover valve “1” Damage/faulty Replace. TIP Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration. The rollover valve must be in an upright posi- tion when checking the airflow. EAS26700 INSTALLING THE FUEL PUMP 1. Install: Fuel pump gasket “1” Fuel pump Fuel pump bracket TIP Do not damage the installation surfaces of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Install the fuel pump gasket with its lip “a” fac- ing up. 12 T R.. Fuel pump bolt 4.0 Nm (0.40 m ·kgf, 2.9 ft· lbf) 1 New
haha FUEL TANK 7-5 Align the projection “b” on the fuel pump with the punch mark “c” on the fuel tank. Align the slot in the fuel pump bracket with the projection “b” on the fuel pump. Tighten the fuel pump bolts in the proper tight- ening sequence as shown. EAS23P1001 INSTALLING THE FUEL TANK 1. Temporarily: Fuel tank bolt (rear side) TIP Temporarily tighten the fuel tank bolt. 2. Install: Fuel hose (fuel rail side) NOTICE ECA23P1091 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed. TIP Install the fuel hose securely onto the fuel rail until a distinct “click” is heard. To install the fuel hose onto the fuel rail, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown. 3. Install: Fuel hose (fuel pump side) Fuel hose holder NOTICE ECA23P1001 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled. TIP Install the fuel hose connector securely onto the fuel tank until a distinct “click ” is heard, and then make sure that it does not come loose. After installing the fuel hose holder “1”, make sure that the sections “a”, “b” , and “c” of the holder are installed securely. 4. Tighten: Fuel tank bolts (front side) 5. Tighten: Fuel tank bolt (rear side) a1 3 5 2 64 1 c b FWD T R.. Fuel tank bolt (front side) 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) T R.. Fuel tank bolt (rear side) 16 Nm (1.6 m ·kgf, 12 ft· lbf) 1 1 a b c
haha THROTTLE BODIES 7-6 EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q ’ty Remarks Fuel tank Refer to “FUEL TANK ” on page 7-1. Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. 1 Accelerator position sensor coupler 1 Disconnect. 2 Throttle position sensor coupler 1 Disconnect. 3 Throttle servo motor coupler 1 Disconnect. 4 Injector #2 coupler 1 Disconnect. 5 Injector #1 coupler 1 Disconnect. 6 Intake air pressure sensor coupler 1 Disconnect. 7 Throttle cable (decelerator cable) 1 Disconnect. 8 Throttle cable (accelerator cable) 1 Disconnect. 9 Canister purge hose (throttle body to hose joint) 1 For California only 7 8 1 2 3 9 4 5 6 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 3.0 Nm (0.30 m kgf, 2.2 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R.
haha THROTTLE BODIES 7-7 Removing the throttle bodies Order Job/Parts to remove Q ’ty Remarks 10 Throttle body joint clamp screw 2 Loosen. 11 Throttle bodies 1 12 Throttle body joint 2 For installation, reverse the removal proce- dure. 11 12 12 10 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 3.0 Nm (0.30 m kgf, 2.2 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R.
haha THROTTLE BODIES 7-8 Removing the injectors Order Job/Parts to remove Q ’ty Remarks 1 Intake air pressure sensor 1 2 Negative pressure hose 1 3 Accelerator position sensor 1 4 Throttle position sensor 1 5Fuel rail 1 6Injector 2 For installation, reverse the removal proce- dure. 5 6 6 1 2 3 4 New New 3.5 Nm (0.35 m kgf, 2.5 ft Ibf)T.R. 3.5 Nm (0.35 m kgf, 2.5 ft Ibf)T.R. 3.5 Nm (0.35 m kgf, 2.5 ft Ibf)T.R. 5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R.
haha THROTTLE BODIES 7-9 EAS23P1077 CHECKING THE INJECTORS (BEFORE REMOVING) 1. Check: Injectors Use the diagnostic code number “ d:36–d:37”. Refer to “DIAGNOSTIC MODE ” on page 8-34. EAS23P1078 REMOVING THE INJECTORS WARNING EWA23P1029 Check the injectors in a well-ventilated area free of combustible materials. Make sure that there is no smoking or use of electric tools in the vicinity of the injectors. Be careful when disconnecting the fuel hose. Any remaining pressure in the fuel hose may cause the fuel to spray out. Place a container or rag under the hose to catch any fuel that spills. Always clean up any spilt fuel immediately. Turn the main switch to “OFF ” and discon- nect the negative battery lead from the bat- tery terminal before removing the injectors. 1. Remove: Fuel rail “1” ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Remove the fuel rail screws “2” as shown. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS23P1079 CHECKING THE INJECTORS 1. Check: Injectors Obstruction Replace and check the fuel pump/fuel supply system. Deposit Replace. Damage Replace. 2. Check: Injector resistance Refer to “CHECKING THE FUEL INJEC- TORS ” on page 8-145. EAS23P1080 CHECKING AND CLEANING THE THROTTLE BODIES TIP Clean the throttle bodies only if they cannot be synchronized using the bypass air screws. Be- fore cleaning the throttle bodies, check the fol- lowing items: Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Cylinder head breather hose WARNING EWA23P1030 If the throttle bodies are subjected to strong shocks or dropped during cleaning, replace them as a set. 1. Check: Throttle bodies Cracks/damage Replace the throttle bod- ies. TIP If the protector “a” is scratched or damaged, re- place the throttle bodies. 2. Clean: Throttle bodies NOTICE ECA23P1066 Observe the following precautions; other- wise, the throttle bodies may not operate properly. Do not open the throttle valves quickly. Do not subject the throttle bodies to exces- sive force. Wash the throttle bodies in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. 1 2 a