2012 Na Yamaha Super Tenere Manual

haha CLUTCH
5-56
Removing the clutch master cylinder Order Job/Parts to remove Q ’ty Remarks
11 Clutch switch coupler 1 Disconnect.
12 Clutch switch 1
13 Clutch hose union bolt 1
14 Clutch hose gasket 2
15 Clutch hose 1
16 Clutch master cylinder holder 1
17 Clutch master cylinder 1
For installation, reverse the removal proce-
dure.
16
11
17
14
15
12
13
SNewNew
LT
1.0 Nm (0.10 m
kgf, 0.72 ft 
Ibf)T.R.
3.8 Nm (0.38 m 
kgf, 2.8 ft 
Ibf)T.R.
4.5 Nm (0.45 m 
kgf, 3.3 ft 
Ibf)T.R.
6 Nm (0.6 m 
kgf, 4.3...

haha CLUTCH
5-57
Disassembling the clutch master cylinder Order Job/Parts to remove Q ’ty Remarks
1 Clutch master cylinder push rod 1
2 Clutch master cylinder kit 1
3 Clutch master cylinder body 1 For assembly, reverse the disassembly pro-
cedure.
3
21
New
BF
S  

haha CLUTCH
5-58
Removing the clutch release cylinder Order Job/Parts to remove Q ’ty Remarks
Clutch fluid Drain.
Refer to 
“BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM ” on page 3-12.
1 Clutch hose union bolt 1
2 Clutch hose gasket 2
3 Clutch hose 1 Disconnect.
4 Clutch release cylinder 1
5 Dowel pin 2
6 Clutch release cylinder plate 1
7 Oil seal 1
For installation, reverse the removal proce-
dure.
New
New
LTLT
LT
LT
LS
6 5
5
4 1
3
7
2
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
10 Nm (1.0 m 
kgf, 7.2 ft ...

haha CLUTCH
5-59
EAS25070
REMOVING THE CLUTCH
1. Remove: Clutch cover  “1”
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. 
2. Remove:
Clutch spring plate retainer  “1”
 Clutch spring plate  “2”
TIP
Loosen the clutch spring plate retainer bolts in 
stages and in a crisscross pattern.
3. Remove:
Friction plates
 Clutch plates
TIP
Before removing friction plate 1, put an identifi-
cation mark “a”  on the...

haha CLUTCH
5-60
TIP
There is a built-in damper between the clutch 
boss and the clutch plate. It is not necessary to 
remove the wire circlip  “4” and disassemble the 
built-in damper unless there is serious clutch 
chattering.
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
Friction plate
Damage/wear   Replace the friction plates 
as a set.
2. Measure: Friction plate thickness
Out of specification   Replace the friction 
plates as a...

haha CLUTCH
5-61
2. Check: Clutch spring plate seat
Damage   Replace.
3. Measure: Clutch spring free height
Out of specification   Replace the clutch 
spring plate.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check: Clutch housing dogs
Damage/pitting/wear   Deburr the clutch 
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check: Bearing
Damage/wear   Replace the bearing and 
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1....

haha CLUTCH
5-62
Excessive noise during operation   Replace 
the clutch housing and crankshaft as a set.
EAS25250
INSTALLING THE CLUTCH
1. Install: Thrust plate  “1”
 Spacer
 Clutch housing
TIP
Install the thrust plate  “1” with the paint mark  “a” 
facing out.
2. Install:
Clutch boss assembly  “1”
TIP
If the wire circlip  “2” has been removed, care-
fully install a new one.
 Install the clutch damper spring  “3” with the 
“OUTSIDE ” mark facing out.
3. Install: Clutch boss assembly  “1”
...

haha CLUTCH
5-63
6. Install: Clutch spring plate  “1”
 Clutch spring plate retainer  “2”
TIP
Tighten the clutch spring plate retainer bolts in 
stages and in a crisscross pattern.
7. Install:
Clutch cover damper  “1”
 Clutch cover damper plate  “2”
TIP
Align the arrow mark “a” on the clutch cover 
damper with the arrow mark  “b” on the clutch 
cover damper plate. 8. Install:
Clutch cover  “1”
TIP
Tighten the clutch cover bolts in the proper tight-
ening sequence as shown.
EAS25280
DISASSEMBLING THE...

haha CLUTCH
5-64
 Clutch fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt fluid immediately.
 Avoid clutch fluid coming into contact with 
the eyes as it can cause serious injury.
 First aid for clutch fluid entering the eyes:
 Flush with water for 15 minutes and get im-
mediate medical attention.
TIP
Before disassembling the clutch master cylinder, 
drain the clutch fluid from the entire clutch sys-
tem.
1. Remove:
Clutch hose union bolt “1”
 Clutch hose...

haha CLUTCH
5-65
2. Install: Clutch hose gaskets  “1” 
 Clutch hose  “2”
 Clutch hose union bolt “3”
WARNING
EWA23P1014
Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to  “CABLE 
ROUTING ” on page 2-43.
NOTICE
ECA23P1041
When installing the clutch hose onto the 
clutch master cylinder, make sure the clutch 
pipe  “a” touches the projection  “b” as 
shown.
TIP
Turn the handlebars to the left and to the right to 
make sure the clutch hose does not touch other 
parts...