2012 Na Yamaha Super Tenere Manual
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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....
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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...
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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...
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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...
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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...
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haha 6 COOLING SYSTEM RADIATOR ...................................................................................................... 6-1 CHECKING THE RADIATOR .................................................................... 6-3 INSTALLING THE RADIATOR .................................................................. 6-3 THERMOSTAT ................................................................................................ 6-4 CHECKING THE...
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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...