2012 Na Yamaha Super Tenere Manual

haha CYLINDER AND PISTONS
5-36
EAS24370
CYLINDER AND PISTONS Removing the cylinder and pistons
Order Job/Parts to remove Q ’ty Remarks
Cylinder head Refer to “CYLINDER HEAD ” on page 5-25.
1 Water jacket cover 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 4
6 Piston pin 2
7Piston 2
8Top  ring 2
9 2nd ring 2
10 Oil ring 2
For installation, reverse the removal proce-
dure.
5
5
6
7
8
9
10
4
4
2
3
1
LTLT
E
E
New
New
E
New
LS
LS
New
E
New
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.  

haha CYLINDER AND PISTONS
5-37
EAS24380
REMOVING THE PISTONS
The following procedure applies to both of the 
pistons.
1. Remove: Piston pin clips  “1”
 Piston pin  “2”
 Piston  “3”
NOTICE
ECA13810
Do not use a hammer to drive the piston pin 
out.
TIP
Before removing the piston pin clips, cover the 
crankcase opening with a clean rag to prevent 
the piston pin clips from falling into the crank-
case.
 For reference during installation, put an identi-
fication mark on each piston crown.
 Before...

haha CYLINDER AND PISTONS
5-38
b. If out of specification, replace the cylinder,  and replace the piston and piston rings as a 
set.
c. Measure piston skirt diameter D  “a” with the 
micrometer.
d. If out of specification, replace the piston and  piston rings as a set.
e. Calculate the piston-to-cylinder clearance 
with the following formula.
f. If out of specification, replace the cylinder,  and replace the piston and piston rings as a 
set.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲EAS24430
CHECKING...

haha CYLINDER AND PISTONS
5-39
3. Measure: Piston ring end gap
Out of specification   Replace the piston 
ring.
TIP
The oil ring expander spacer ’s end gap cannot 
be measured. If the oil ring rail ’s gap is exces-
sive, replace all three piston rings.
EAS24440
CHECKING THE PISTON PINS
The following procedure applies to both of the 
piston pins.
1. Check:
Piston pin
Blue discoloration/grooves   Replace the 
piston pin and then check the lubrication sys-
tem.
2. Measure:
Piston pin outside diameter...

haha CYLINDER AND PISTONS
5-40
1. Install: Oil ring expander “1”
 Lower oil ring rail  “2”
 Upper oil ring rail  “3”
 2nd ring “4”
 Top ring “5”
TIP
Install the oil ring expander as shown in the il-
lustration.
 Be sure to install the piston rings so that the 
manufacturer marks face up.
2. Install: Piston  “1”
 Piston pin  “2”
 Piston pin clips  “3” 
TIP
Apply engine oil onto the piston pin.
 Make sure the punch mark  “a” on the piston 
points towards the exhaust side of the engine.
...

haha CYLINDER AND PISTONS
5-41
1  

haha GENERATOR AND STARTER CLUTCH5-42
EAS24480
GENERATOR AND STARTER CLUTCHRemoving the stator coil, generator rotor and starter clutch
Order Job/Parts to remove Q ’ty Remarks
Engine oil Drain.
Refer to 
“CHANGING THE ENGINE OIL ” on 
page 3-24.
Side cowlings Refer to 
“GENERAL CHASSIS ” on page 
4-1.
Engine guard Refer to “ENGINE REMOVAL ” on page 5-3.
Fuel tank Refer to “FUEL TANK ” on page 7-1.
1 Stator coil coupler 1 Disconnect.
2 Engine guard bracket 1
3 Holder (fuel tank overflow hose and fuel...

haha GENERATOR AND STARTER CLUTCH5-43
Removing the stator coil, generator rotor and starter clutchOrder Job/Parts to remove Q ’ty Remarks
7 Dowel pin 2
8 Stator coil lead holder 1
9 Stator coil 1
10 Generator rotor 1
11 Woodruff key 1
12 Starter clutch idle gear shaft 1
13 Starter clutch idle gear 1
14 Torque limiter 1
15 Starter clutch gear 1
16 Starter clutch 1
17 Washer 1
For installation, reverse the removal proce-
dure.
LT
LT
E
LT
E
E
LTLT
E
E
E
LTLT
14
13
12
15
16
17
(3)
(8)
10
11
7 7
9
8
10 Nm...

haha GENERATOR AND STARTER CLUTCH5-44
EAS24490
REMOVING THE GENERATOR
1. Remove:Generator rotor bolt  “1”
 Washer
TIP
While holding the generator rotor “2”  with the 
sheave holder “3” , loosen the generator rotor 
bolt.
2. Remove:
Generator rotor  “1”
(with the flywheel puller  “2”)
 Woodruff key
NOTICE
ECA13880
To protect the end of the crankshaft, place an 
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.
TIP
Install the flywheel puller bolts to the...

haha GENERATOR AND STARTER CLUTCH5-45
▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Install the starter clutch gear  “1” onto the gen-
erator rotor  “2” and hold the generator rotor.
b. When turning the starter clutch gear clock- wise “A” , the starter clutch and the starter 
clutch gear should engage, otherwise the 
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter-
clockwise  “B”, it should turn freely, otherwise 
the starter clutch is faulty and must be...