2012 Na Yamaha Super Tenere Manual

							
haha 4
CHASSIS
GENERAL CHASSIS ....................................................................................... 4-1
INSTALLING THE SEATS........................................................................\
. 4-2
INSTALLING THE CARRIERS .................................................................. 4-2
REMOVING THE ABS UNIT COVER ....................................................... 4-7
INSTALLING THE ABS UNIT COVER ...................................................... 4-7
REMOVING THE SIDE COWLINGS ......................................................... 4-9
INSTALLING THE SIDE COWLINGS ....................................................... 4-9
INSTALLING THE ELECTRICAL COMPONENTS TRAY ....................... 4-14
ASSEMBLING THE HEADLIGHT ........................................................... 4-17
INSTALLING THE HEADLIGHT ASSEMBLY AND WINDSHIELD ......... 4-17
REMOVING THE AIR FILTER CASE...................................................... 4-19
FRONT WHEEL ............................................................................................. 4-20
REMOVING THE FRONT WHEEL.......................................................... 4-23
DISASSEMBLING THE FRONT WHEEL ................................................ 4-23
CHECKING THE FRONT WHEEL .......................................................... 4-23
MAINTENANCE OF THE FRONT WHEEL SENSOR AND 
SENSOR ROTOR .................................................................................. 4-24
ASSEMBLING THE FRONT WHEEL ...................................................... 4-25
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-26
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-27
REAR WHEEL ............................................................................................... 4-29
REMOVING THE REAR WHEEL ............................................................ 4-32
DISASSEMBLING THE REAR WHEEL .................................................. 4-32
CHECKING THE REAR WHEEL............................................................. 4-32
MAINTENANCE OF THE REAR WHEEL SENSOR AND  SENSOR ROTOR .................................................................................. 4-33
ASSEMBLING THE REAR WHEEL ........................................................ 4-33
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-34
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ...................... 4-34
FRONT BRAKE ............................................................................................. 4-36
INTRODUCTION ..................................................................................... 4-43
CHECKING THE FRONT BRAKE DISCS ............................................... 4-43
REPLACING THE FRONT BRAKE PADS .............................................. 4-44
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-45
DISASSEMBLING THE FRONT BRAKE CALIPERS.............................. 4-45
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-46
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-46
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-47
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-48
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-48
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-49
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-49  
						

							
haha REAR BRAKE............................................................................................... 4-51
INTRODUCTION ..................................................................................... 4-58
CHECKING THE REAR BRAKE DISC.................................................... 4-58
REPLACING THE REAR BRAKE PADS................................................. 4-58
REMOVING THE REAR BRAKE CALIPER ............................................ 4-59
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-59
CHECKING THE REAR BRAKE CALIPER ............................................. 4-60
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-60
INSTALLING THE REAR BRAKE CALIPER ........................................... 4-60
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-62
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................ 4-62
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-62
ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-62
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-63
ABS (Anti-Lock Brake System) ................................................................... 4-65
REMOVING THE HYDRAULIC UNIT ASSEMBLY ................................. 4-68
CHECKING THE HYDRAULIC UNIT ASSEMBLY .................................. 4-69
CHECKING THE BRAKE PIPES............................................................. 4-69
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-69
HYDRAULIC UNIT OPERATION TESTS................................................ 4-70
TRIAL RUN.............................................................................................. 4-74
HANDLEBAR ................................................................................................ 4-75
REMOVING THE HANDLEBAR .............................................................. 4-78
CHECKING THE HANDLEBAR .............................................................. 4-78
INSTALLING THE HANDLEBAR ............................................................ 4-78
FRONT FORK................................................................................................ 4-81 REMOVING THE FRONT FORK LEGS .................................................. 4-84
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-84
CHECKING THE FRONT FORK LEGS .................................................. 4-85
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-86
INSTALLING THE FRONT FORK LEGS ................................................ 4-90
STEERING HEAD .......................................................................................... 4-91
REMOVING THE LOWER BRACKET..................................................... 4-93
CHECKING THE STEERING HEAD ....................................................... 4-93
INSTALLING THE STEERING HEAD ..................................................... 4-93
REAR SHOCK ABSORBER ASSEMBLY .................................................... 4-95
HANDLING THE REAR SHOCK ABSORBER ........................................ 4-97
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-97
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-97
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-97
CHECKING THE CONNECTING ARM AND RELAY ARM ..................... 4-98
INSTALLING THE RELAY ARM.............................................................. 4-98
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-98  
						

							
haha SWINGARM................................................................................................... 4-99
REMOVING THE SWINGARM.............................................................. 4-101
CHECKING THE SWINGARM .............................................................. 4-101
INSTALLING THE SWINGARM ............................................................ 4-101
SHAFT DRIVE ............................................................................................. 4-103
TROUBLESHOOTING .......................................................................... 4-107
CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND  CHECKING THE SHAFT DRIVE FOR LEAKS..................................... 4-108
MEASURING THE FINAL GEAR BACKLASH ...................................... 4-108
ADJUSTING THE FINAL GEAR BACKLASH ....................................... 4-109
MEASURING THE RING-GEAR-TO-STOPPER-BOLT  CLEARANCE........................................................................................ 4-110
ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT 
CLEARANCE........................................................................................ 4-110
DISASSEMBLING THE FINAL DRIVE ASSEMBLY ............................. 4-111
REMOVING AND INSTALLING THE BEARINGS................................. 4-112
ASSEMBLING THE FINAL DRIVE ASSEMBLY ................................... 4-113
ALIGNING THE FINAL DRIVE PINION GEAR AND RING  GEAR ................................................................................................... 4-113
CHECKING THE DRIVE SHAFT........................................................... 4-116
INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY .... 4-117  
						

							
haha GENERAL CHASSIS
4-1
EAS21830
GENERAL CHASSIS Removing the seats and carriers
Order Job/Parts to remove Q ’ty Remarks
1 Rider seat 1
2 Hexagon wrench 1
3 Passenger seat 1
4 Rider seat height position adjuster 1
5 Standard carrier 1
6 Standard carrier bracket 1
7 Left grab bar 1
8 Right grab bar 1
9 Additional carrier 1
10 Seat bracket 1
For installation, reverse the removal proce-
dure.
8 6
2 1
4 3
7
(4)
5
9
10
20 Nm (2.0 m 
kgf, 14 ft 
Ibf)T.R.
20 Nm (2.0 m 
kgf, 14 ft 
Ibf)T.R.
32 Nm (3.2 m 
kgf, 23 ft 
Ibf)T.R.
16 Nm (1.6 m 
kgf, 12 ft 
Ibf)T.R.
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.R..7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.R..7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
32 Nm (3.2 m 
kgf, 23 ft 
Ibf)T.R.  
						

							
haha GENERAL CHASSIS
4-2
EAS23P1003
INSTALLING THE SEATS
1. Install: Passenger seat  “1”
TIP
Insert the projection “a”  on the rear of the pas-
senger seat into the seat holder  “b” in the addi-
tional carrier.
2. Install:
Rider seat height position adjuster  “1”
 Rider seat “2”
TIP
The rider seat height can be adjusted to one of 
two positions to suit the rider ’s preference.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
To install the rider seat in the high posi-
tion
a. Install the rider seat height position adjuster  so that the match mark  “a” on the adjuster is 
aligned with the  “H” mark  “b” on the seat 
bracket.
b. Insert the projection “c”  on the rear of the rider 
seat into the seat holder  “d” in the seat brack-
et, and then push the front of the seat down 
to lock it in place.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
To install the rider seat in the low position
a. Install the rider seat height position adjuster  so that the match mark  “a” on the adjuster is 
aligned with the  “L” mark  “b” on the seat 
bracket.
b. Insert the projection “c”  on the rear of the rider 
seat into the seat holder  “d” in the seat brack-
et, and then push the front of the seat down 
to lock it in place.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS23P1005
INSTALLING THE CARRIERS
NOTICE
ECA23P1058
Do not lift the vehicle by either carrier.
This vehicle is equipped with a standard carrier 
“1”  and an additional carrier “2” . To use the stan-
dard carrier only, perform steps (1) to (4). To use 
the standard carrier and additional carrier, per-
form steps (1) to (3), (5), and (6).
b
a
1
b a
1
c
d
2
a
b
1
c
2
d  
						

							
haha GENERAL CHASSIS
4-3
Standard carrier
Additional carrier
1. Install: Seat bracket  “1”
TIP
Make sure that the spring nuts  “2” contact the 
edges “a”  of the recesses in the seat bracket.
Temporarily tighten the seat bracket bolts “3”.
2. Install: Additional carrier  “1”
TIP
Temporarily tighten the additional carrier bolts 
“2”. 3. Tighten:
 Seat bracket bolts  “1”
  Additional carrier bolts  “2”
TIP
Before tightening the bolts, make sure to align 
the bolt holes “a” in the additional carrier with the 
bolt holes “b”  in the seat bracket.
4. Install: Grab bars  “1”
 Washers  “2”
 Standard carrier bracket
 Standard carrier
 Passenger seat
1
2
a2a 2
1
3
3
T R..  Seat bracket bolt
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
Additional carrier bolt 7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
3. Spring nut
T R..  Grab bar bolt
32 Nm (3.2 m ·kgf, 23 ft· lbf)
Standard carrier bracket bolt 20 Nm (2.0 m ·kgf, 14 ft· lbf)
Standard carrier bolt 20 Nm (2.0 m ·kgf, 14 ft· lbf)
Passenger seat bolt 16 Nm (1.6 m ·kgf, 12 ft· lbf)
2
1
a
b3
2
1
1  
						

							
haha GENERAL CHASSIS
4-4
TIP
Align the slots  “a” in the washer with the projec-
tions “b”  on the grab bar.
5. Remove: Rubber plug “1”
6. Install: Standard carrier  “1”
TIP
Use the two standard carrier bracket bolts  “2” 
and the standard carrier bolt (45 mm) “3”.
T R.. Standard carrier bolt
20 Nm (2.0 m· kgf, 14 ft·lbf)
1
2 a
b
1
3
1
2  
						

							
haha GENERAL CHASSIS
4-5
Removing the tail/brake light assembly Order Job/Parts to remove Q ’ty Remarks
Rear fuel tank bracket/Seat lock assembly Refer to  “FUEL TANK” on page 7-1.
Standard carrier bracket/Seat bracket Refer to  “Removing the seats and carriers”.
1 ABS unit cover 1
2 Rear turn signal light coupler 2 Disconnect.
3 License plate light coupler 1 Disconnect.
4 Tail/brake light coupler 1 Disconnect.
5 Tail/brake light assembly 1
6 Lean angle sensor coupler 1 Disconnect.
7 Lean angle sensor 1
8 Frame ground lead 1
9 Lean angle sensor sub-wire harness coupler 1 Disconnect.
10 Lean angle sensor sub-wire harness 1
1
2
3
910
6
8
7
4
5
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
15 Nm (1.5 m 
kgf, 11 ft 
Ibf)T.R.
15 Nm (1.5 m 
kgf, 11 ft 
Ibf)T.R.
1.0 Nm (0.10 m 
kgf, 0.72 ft 
Ibf)T.R.
3.0 Nm (0.30 m 
kgf, 2.2 ft 
Ibf)T.R.  
						

							
haha GENERAL CHASSIS
4-6
Removing the tail/brake light assembly Order Job/Parts to remove Q ’ty Remarks
11 Seat lock cable 1
12 Seat lock bracket 1
13 Seat lock 1
For installation, reverse the removal proce-
dure.
11
12
13
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
15 Nm (1.5 m 
kgf, 11 ft 
Ibf)T.R.
15 Nm (1.5 m 
kgf, 11 ft 
Ibf)T.R.
1.0 Nm (0.10 m 
kgf, 0.72 ft 
Ibf)T.R.
3.0 Nm (0.30 m 
kgf, 2.2 ft 
Ibf)T.R.  
						

							
haha GENERAL CHASSIS
4-7
EAS23P1103
REMOVING THE ABS UNIT COVER
1. Remove: ABS unit cover  “1”
TIP
Remove the quick fastener screw  “2”, and then 
pull the ABS unit cover off as shown in the illus-
tration.
EAS23P1068
INSTALLING THE ABS UNIT COVER
1. Install: Frame ground lead  “1”
TIP
Make sure that the frame ground lead terminal 
“a” contacts the stopper  “b” on the frame.
2. Install: Plastic locking tie  “1”
TIP
Fold the ABS test coupler lead  “2”, and then 
fasten the ABS test coupler lead, lean angle 
sensor sub-wire harness, rear turn signal light 
leads, tail/brake light lead, and license plate 
light lead with the plastic locking tie.
 Position the plastic locking tie 40 –60 mm 
(1.57 –2.36 in)  “a” from the edge of the holder. 3. Install:
ABS unit cover  “1”
TIP
Insert the projections “a”  on the ABS unit cover 
into the slots  “b” in the rear fender assembly, and 
then install the quick fastener screw.
T R..  Frame ground lead bolt
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
12
1
b
a
1
2
a
a 1
b