2012 Na Yamaha Super Tenere Manual

							
haha HANDLEBAR
4-78
EAS22860
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
2. Remove: Handlebar grip “1”
TIP
Blow compressed air between the left handlebar 
and the handlebar grip, and gradually push the 
grip off the handlebar.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
Handlebar
Bends/cracks/damage   Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS22931
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
2. Install:
Handlebar “1”
 Upper handlebar holders “2”
NOTICE
ECA23P1061
First, tighten the bolts on the front side of the 
handlebar holder, and then on the rear side.
TIP
The upper handlebar holders should be in-
stalled with the punch marks  “a” facing for-
ward.
 Align the punch mark  “b” on the handlebar with 
the upper surface of the lower handlebar hold-
er.
3. Install: Throttle grip “1”
 Throttle cables
 Throttle cable housings  “2”
TIP
Make sure that the distance  “a” between the 
end of the handlebar and the end of the throttle 
grip is 11 –13 mm (0.43 –0.51 in).
 Align the projection  “b” on the throttle cable 
housing with the hole  “c” in the handlebar.
T R..  Upper handlebar holder bolt
28 Nm (2.8 m· kgf, 20 ft·lbf)
T R..  Throttle cable housing bolt
3.8 Nm (0.38 m ·kgf, 2.8 ft· lbf)
2
1
a
b
a
1
2
c
b   
						

							
haha HANDLEBAR
4-79
4. Install: Right handlebar switch  “1”
TIP
Align the projection “a” on the right handlebar 
switch with the hole  “b” on the handlebar.
5. Install: Front brake master cylinder assembly
 Front brake master cylinder holder  “1”
TIP
Install the brake master cylinder holder with the 
“UP ” mark facing up.
 Align the mating surfaces of the brake master 
cylinder holder with the punch mark  “a” on the 
handlebar.
 First, tighten the upper bolt, then the lower bolt.
6. Install: Right grip end “1”
 Right hand shield  “2”
TIP
There should be 1–3 mm (0.04 –0.12 in) of clear-
ance  “a” between the throttle grip  “3” and the grip 
end.
7. Install:
Left handlebar switch  “1”
TIP
Align the projection “a” on the left handlebar 
switch with the hole  “b” in the handlebar.
8. Install: Clutch master cylinder assembly  “1”
 Clutch master cylinder holder  “2”
TIP
The clutch master cylinder holder should be in-
stalled with the punch mark “a”  forward.
T R.. Right handlebar switch screw
3.5 Nm (0.35 m ·kgf, 2.5 ft ·lbf)
T R..  Front brake master cylinder hold-
er bolt
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
1
a b
1
a
T R.. 
Right grip end bolt
27 Nm (2.7 m ·kgf, 20 ft· lbf)
Right upper hand shield bolt 3.8 Nm (0.38 m ·kgf, 2.8 ft ·lbf)
Right lower hand shield bolt 4.5 Nm (0.45 m ·kgf, 3.3 ft ·lbf)
LOCTITE ®
T R..  Left handlebar switch screw
3.5 Nm (0.35 m ·kgf, 2.5 ft· lbf)
T R.. Clutch master cylinder holder 
bolt
14 Nm (1.4 m ·kgf, 10 ft· lbf)
1
a
3 2
1
a
b  
						

							
haha HANDLEBAR
4-80
 Align the mating surfaces of the clutch master 
cylinder holder with the punch mark  “b” on the 
handlebar.
 First, tighten the front bolt, then the rear bolt.
9. Install: Handlebar grip “1”
 Left grip end  “2”
 Left hand shield  “3”
▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the 
end of the left handlebar.
b. Slide the handlebar grip over the end of the  left handlebar.
TIP
Make sure that the distance  “a” between the end 
of the handlebar and the end of the handlebar 
grip is 11– 13 mm (0.43 –0.51 in).
c. Wipe off any excess rubber adhesive with a  clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
d. Install the left grip end and left hand shield.
TIP
There should be 1 –3 mm (0.04 –0.12 in) of clear-
ance  “b” between the handlebar grip and the grip 
end.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
10.Adjust: Throttle cable free play
Refer to “ CHECKING THE THROTTLE GRIP 
OPERATION ” on page 3-30.
T R..  Left grip end bolt
27 Nm (2.7 m· kgf, 20 ft·lbf)
Left upper hand shield bolt 3.8 Nm (0.38 m ·kgf, 2.8 ft ·lbf)
Left lower hand shield bolt 4.5 Nm (0.45 m ·kgf, 3.3 ft ·lbf)
LOCTITE ®
a
2
b1
a1
  Throttle cable free play
3.0– 5.0 mm (0.12– 0.20 in)
b21
3  
						

							
haha FRONT FORK
4-81
EAS22950
FRONT FORK Removing the front fork legs
Order Job/Parts to remove Q ’ty Remarks
The following procedure applies to both of 
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-20.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5Front  fork leg 1
For installation, reverse the removal proce-
dure.
1 5
4
2
3
7 Nm (0.7 m

kgf, 5.1 ft 
Ibf)T.R.
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.
20 Nm (2.0 m 
kgf, 14 ft 
Ibf)T.R.
23 Nm (2.3 m 
kgf, 17 ft 
Ibf)T.R.
26 Nm (2.6 m 
kgf, 19 ft 
Ibf)T.R.
7 Nm (0.7 m 
kgf, 5.1 ft 
Ibf)T.R.  
						

							
haha FRONT FORK
4-82
Disassembling the front fork legs Order Job/Parts to remove Q ’ty Remarks
The following procedure applies to both of 
the front fork legs.
1 Cap bolt 1
2O-ring 1
3 Damper adjusting rod 1
4Nut 1
5Collar 1
6Washer 1
7 Spacer 1
8 Fork spring 1
9 Fork spring guide 1
10 Damper rod assembly bolt 1
11 Copper washer 1
1011
1
2
3
4
5 6
7
8
9
New
New
LTLT
15 Nm (1.5 m

kgf, 11 ft 
Ibf)T.R.
23 Nm (2.3 m 
kgf, 17 ft 
Ibf)T.R.
LS
LS  
						

							
haha FRONT FORK
4-83
Disassembling the front fork legs Order Job/Parts to remove Q ’ty Remarks
12 Damper rod assembly 1
13 Dust seal 1
14 Oil seal clip 1
15 Outer tube 1
16 Oil seal 1
17 Washer 1
18 Outer tube bushing 1
19 Inner tube bushing 1
20 Inner tube 1
For assembly, reverse the disassembly pro-
cedure.
20
12
15
18
17
16
14
13
New
New
New
New
New
LTLT
15 Nm (1.5 m 
kgf, 11 ft 
Ibf)T.R.
23 Nm (2.3 m 
kgf, 17 ft 
Ibf)T.R.
19
LS
LS  
						

							
haha FRONT FORK
4-84
EAS22960
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the 
front wheel is elevated.
2. Loosen: Upper bracket pinch bolt  “1”
 Cap bolt “2”
 Lower bracket pinch bolts  “3”
WARNING
EWA13640
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
3. Remove:
Front fork leg
EAS22990
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Remove: Cap bolt “1”
(from the damper rod assembly)
 Washer  “2”
 Spacer “3”
 Nut “4” 
Collar  “5”
▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Press down on the spacer with the fork spring 
compressor  “6” and then secure the com-
pressor with a suitable tool  “7”.
b. Hold the spring preload adjusting bolt “8”  and 
loosen the nut  “4”.
c. Remove the cap bolt.
d. Remove the fork spring compressor.
e. Remove the washer, spacer, nut, and collar.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Drain: Fork oil
TIP
Stroke the damper rod  “1” several times while 
draining the fork oil.
3. Remove:
Damper rod assembly bolt
 Damper rod assembly
TIP
While holding the damper rod with the damper 
rod holder  “1”, loosen the damper rod assembly 
bolt.
2
1
3
  Fork spring compressor
90890-01441
YM-01441
1 8
2
57
4
3
7
6    
						

							
haha FRONT FORK
4-85
4. Remove: Dust seal  “1”
 Oil seal clip “2”
(with a flat-head screwdriver)
NOTICE
ECA23P1033
Do not scratch the outer tube.
5. Remove:
Outer tube
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a 
vise with soft jaws.
c. Separate the outer tube from the inner tube  by pulling the outer tube forcefully but careful-
ly.
NOTICE
ECA23P1062
Excessive force will damage the bushings. 
Damaged bushings must be replaced.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS23011
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Check: Inner tube
 Outer tube
Bends/damage/scratches   Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it.
2. Measure:
Fork spring free length “a”
Out of specification   Replace.
3. Check: Damper rod assembly
Damage/wear   Replace.
Obstruction   Blow out all of the oil passag-
es with compressed air.
 Damper adjusting rod
Bends/damage   Replace.
  Damper rod holder
90890-01423
Damping rod holder YM-01423
1
1
2
  Fork spring free length
427.4 mm (16.83 in)
Limit 418.9 mm (16.49 in)
a  
						

							
haha FRONT FORK
4-86
NOTICE
ECA14200
 The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly 
sensitive to foreign material.
 When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check: Cap bolt O-ring
Damage/wear   Replace.
EAS23041
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
 Make sure the oil levels in both front fork 
legs are equal.
 Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
When assembling the front fork leg, be sure to 
replace the following parts:
–Inner tube bushing
– Outer tube bushing
– Oil seal
– Dust seal
– O-ring
 Before assembling the front fork leg, make 
sure all of the components are clean.
1. Lubricate: Inner tube ’s outer surface
2. Install: Dust seal  “1” 
 Oil seal clip “2” 
 Oil seal  “3” 
 Washer  “4”
 Outer tube bushing “5” 
 Inner tube bushing “6” 
NOTICE
ECA23P1034
Make sure to face the numbered side of the 
oil seal toward the bottom end of the inner 
tube.
TIP
Before installing the oil seal, lubricate its lips 
with lithium-soap-based grease.
 Lubricate the outer surface of the inner tube 
with fork oil.
 Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
3. Install: Outer tube
(to the inner tube)
4. Install:
Outer tube bushing  “1”
 Washer  “2”
(with the fork seal driver  “3”)
 Recommended oil
Suspension oil 01 or equivalent
New
New
New
New
New
  Fork seal driver
90890-01442
Adjustable fork seal driver (36– 46 
mm) YM-01442
4
6New 5
New
1New
2
New
3
New
1
3
2   
						

							
haha FRONT FORK
4-87
5. Install: Oil seal  “1”
(with the fork seal driver  “2”)
6. Install: Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer 
tube’ s groove.
7. Install: Dust seal  “1”
(with the fork seal driver  “2”) 8. Install:
Damper rod assembly  “1”
 Inner tube
NOTICE
ECA23P1063
Allow the damper rod assembly to slide 
slowly down the inner tube until it contacts 
the bottom of the inner tube. Be careful not 
to damage the inner tube.
9. Tighten:
Damper rod assembly bolt  “1”
TIP
While holding the damper rod assembly with the 
damper rod holder “2”, tighten the damper rod 
assembly bolt.
  Fork seal driver
90890-01442
Adjustable fork seal driver (36 –46 
mm) YM-01442
  Fork seal driver
90890-01442
Adjustable fork seal driver (36 –46 
mm) YM-01442
1
2
T R.. 
Damper rod assembly bolt
23 Nm (2.3 m ·kgf, 17 ft· lbf)
LOCTITE ®
  Damper rod holder
90890-01423
Damping rod holder YM-01423
12
1