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2012 Na Yamaha Super Tenere Manual

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Page 411

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...

Page 412

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....

Page 413

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...

Page 414

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...

Page 415

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...

Page 416

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...

Page 417

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...

Page 418

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...

Page 419

haha 6
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1
CHECKING THE RADIATOR .................................................................... 6-3
INSTALLING THE RADIATOR .................................................................. 6-3
THERMOSTAT ................................................................................................ 6-4
CHECKING THE...

Page 420

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...
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