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...

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...

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...

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...

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 ...

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...

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.