2012 Na Yamaha Super Tenere Manual

							
haha SHAFT DRIVE
4-108
 
 NO  
YES  
 
 YES  
NO  
EAS23570
CHECKING THE FINAL DRIVE OIL FOR 
CONTAMINATION AND CHECKING THE 
SHAFT DRIVE FOR LEAKS
1. Drain: Final gear oil
(from the final gear case)
Refer to  “CHANGING THE FINAL GEAR 
OIL ” on page 3-29.
2. Check:
Final gear oil
Large amount of metal particles   Check for 
bearing seizure.
TIP
A small amount of metal particles in the final 
gear oil is normal.
3. Check:
Shaft drive housing
(for oil leaks)
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a. Thoroughly clean the entire vehicle and then 
completely dry it.
b. Apply a leak-locating compound or dry pow- der spray to the shaft drive.
c. Test ride the vehicle long enough to locate a 
leak.
Oil leak   Repair or replace the faulty part(s).
TIP
What may appear to be an oil leak on a new or 
fairly new vehicle, may result from the applica-
tion of a rust preventive coating or excessive 
seal lubrication.
 Always clean the vehicle and recheck the area 
where the leak is thought to originate from.
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EAS23581
MEASURING THE FINAL GEAR BACKLASH
1. Secure the final drive assembly in a vise.
2. Remove: Final gear oil drain bolt
3. Drain:
Final gear oil
(from the final drive assembly)
4. Measure:
Final gear backlash
Out of specification   Adjust.
2. Place the vehicle on the center-
stand so that the rear wheel is ele-
vated and then spin the rear wheel. 
Is the wheel bearing damaged? Rear wheel bearings and shaft drive bear-
ings are probably not damaged. Repeat 
the test or remove and check the compo-
nents.
3. Remove the rear wheel. Is the  wheel bearing damaged? 
Replace the rear wheel bearing.
 Refer to  “REAR WHEEL ” on page 4-29.
Remove and check the drive shaft 
components.
1. Oil seal
2. O-ring
A. Forward
A
2
1
1
2
1  
						

							
haha SHAFT DRIVE
4-109
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a. Install the ring gear fix bolt  “1”, into the final 
gear oil drain hole.
b. Finger tighten the ring gear fix bolt until it  stops the ring gear from moving.
TIP
Do not overtighten the ring gear fix bolt.
c. Install the final gear backlash band  “2” and 
dial gauge  “3”.
d. Gently rotate the coupling gear from engage- ment to engagement.
e. Record the reading on the dial gauge.
f. Remove the dial gauge, final gear backlash  band, and ring gear fix bolt.
g. Rotate the final drive pinion gear 90 °.h. Reinstall the ring gear fix bolt, final gear back-
lash band, and dial gauge.
i. Repeat steps (d) to (h) three more times (for 
a total of four measurements).
j. If any of the readings are over specification,  adjust the final gear backlash.
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EAS23591
ADJUSTING THE FINAL GEAR BACKLASH
1. Remove: Ring gear bearing housing bolts (M10)  “1”
 Ring gear bearing housing bolts (M8)  “2”
TIP
Working in a crisscross pattern, loosen each bolt 
1/4 of a turn. After all of the bolts are fully loos-
ened, remove them.
2. Remove:
Ring gear bearing housing “1”
 Ring gear “2”
 Ring gear shim(s)  “3”
 Thrust washer “4”
3. Adjust:  Final gear backlash
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a. Select the suitable shim(s) and thrust washer 
with the following chart.
  Final gear backlash
0.20– 0.40 mm (0.008– 0.016 in)
 Ring gear fix bolt (M14)
90890-01548
YM-01548
  Final gear backlash band
90890-01511
Middle drive gear lash tool YM-01230
a. Measuring point is 61.0 mm (2.40 in)
b. Measuring point is 7.1 mm (0.28 in)
1
3 a
b
2
Thinner shim
Final gear backlash is in-
creased.
Thicker shim Final gear backlash is de-
creased.
2
2
2
2
1
12
2
1
3 2
4  
						

							
haha SHAFT DRIVE
4-110
b. If it is necessary to increase the final gear  backlash by more than 0.2 mm (0.008 in), re-
duce the ring gear shim thickness by 0.2 mm 
(0.008 in) for every 0.2 mm (0.008 in) in-
crease of thrust washer thickness.
c. If it is necessary to reduce the final gear back-
lash by more than 0.2 mm (0.008 in), in-
crease the ring gear shim thickness by 0.2 
mm (0.008 in) for every 0.2 mm (0.008 in) de-
crease of thrust washer thickness.
TIP
Be sure to use only one thrust washer to obtain 
the thrust washer thickness.
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EAS23600
MEASURING THE RING-GEAR-TO-
STOPPER-BOLT CLEARANCE
1. Remove: Ring gear bearing housing
(along with the ring gear)
Refer to  “ADJUSTING THE FINAL GEAR 
BACKLASH ” on page 4-109.
2. Measure:
Ring-gear-to-stopper-bolt clearance  “a”
Out of specification   Adjust. 3. Install:
Ring gear bearing housing
(along with the ring gear)
EAS23610
ADJUSTING THE RING-GEAR-TO-
STOPPER-BOLT CLEARANCE
1. Remove: Ring gear “1”
 Stopper bolt  “2”
 Stopper bolt shim(s)  “3”
 Ring gear bearing housing “4”
2. Select: Stopper bolt shim(s)
3. Install: Ring gear bearing housing “1”
 Stopper bolt shim(s)  “2”
 Stopper bolt  “3”
 Ring gear “4”
  Ring gear shims
Thickness (mm)0.25 0.30 0.40 0.50
  Thrust washer
Thickness (mm)1.2 1.4 1.6 1.8 2.0
  Ring-gear-to-stopper-bolt clear-
ance
0.30– 0.60 mm (0.012– 0.024 in)
1. Stopper bolt
2. Ring gear
 Stopper bolt shims
Thickness (mm)0.15 0.20
T R..  Stopper bolt
9 Nm (0.9 m ·kgf, 6.5 ft· lbf)
LOCTITE ®
1
3
24    
						

							
haha SHAFT DRIVE
4-111
NOTICE
ECA14320
 The stopper bolt has left-hand threads. To 
tighten the stopper bolt, turn it counter-
clockwise.
Apply LOCTITE ® onto the stopper bolt.
4. Measure: Ring-gear-to-stopper-bolt clearance
TIP
If the ring-gear-to-stopper-bolt clearance is out 
of specification, repeat the above procedure.
EAS23620
DISASSEMBLING THE FINAL DRIVE 
ASSEMBLY
1. Remove:
Ring gear bearing housing bolts (M10)  “1”
 Ring gear bearing housing bolts (M8)  “2”
TIP
Working in a crisscross pattern, loosen each nut 
1/4 of a turn. After all of the nuts are fully loos-
ened, remove them and the bolts.
2. Straighten:
Punched portion  “a” of the coupling gear nut 
“1” 3. Remove:
Coupling gear nut
 Washer
 Coupling gear “1”
(with the coupling gear holding tool “2”)
4. Remove: Bearing retainer
(with the bearing retainer wrench  “1”)
NOTICE
ECA14330
The bearing retainer has left-hand threads. 
To loosen the bearing retainer, turn it clock-
wise.
 Ring-gear-to-stopper-bolt clear-
ance
0.30– 0.60 mm (0.012– 0.024 in)
4
2
31
2
2 2
2
1
12
2
 Coupling gear holding tool
90890-01560
YM-01560
  Bearing retainer wrench
90890-01561
YM-01561
1
a
2
1
1   
						

							
haha SHAFT DRIVE
4-112
5. Remove: Final drive pinion gear
NOTICE
ECA14340
The final drive pinion gear should only be re-
moved if ring gear replacement is necessary.
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a. Install the coupling gear nut “1”.
b. Install the general puller  “2”.
TIP
Fit the jaws of the general puller onto the cou-
pling gear nut.
c. Separate the final drive pinion gear from the 
final gear case.
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EAS23630
REMOVING AND INSTALLING THE 
BEARINGS
1. Check: Bearings
Damage   Replace.
2. Remove: Collar  “1”
 Oil seal  “2”
 Bearing “3”
(with an appropriate press tool  “4” and an ap-
propriate support for the final drive housing) 3. Remove:
Bearing holder  “1”
 Dowel pin  “2”
 Bearing “3”▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Heat the final gear case to approximately 150 
°C (302  °F).
b. Remove the inner race from the final drive  pinion gear.
TIP
The removal of the final drive pinion gear bear-
ing is a difficult procedure and is rarely neces-
sary.
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4. Install:
Bearing 
 Dowel pin
 Bearing holder
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a. Heat the final gear case to approximately 150 
°C (302  °F).
2
1
1
2
3
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haha SHAFT DRIVE
4-113
b. Install the bearing outer races with a socket  or appropriate tool that matches the diameter 
of the races.
c. Install the inner race onto the final drive pin- ion gear.
d. Install the bearing holder and tighten the bolt 
to specification.
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5. Install: Collar  “1”
 Oil seal  “2” 
 Bearing “3”
(with an appropriate press tool  “4” and press)
TIP
The bearing can be reused, but Yamaha recom-
mends installing a new one.
EAS23P1028
ASSEMBLING THE FINAL DRIVE 
ASSEMBLY
1. Install:
Final drive case stud bolts
TIP
Apply LOCTITE ® to the threads of the final 
drive case stud bolts.
 Install the final drive case stud bolts so that the 
specified installed length  “a” is obtained. EAS23640
ALIGNING THE FINAL DRIVE PINION GEAR 
AND RING GEAR
TIP
Aligning the final drive pinion gear and ring gear 
is necessary when any of the following parts are 
replaced:

Final gear case
 Ring gear bearing housing
Any bearing
1. Select: Final drive pinion gear shim(s)  “1”
 Ring gear shim(s)  “2”
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a. Position the final drive pinion gear shim(s) 
and the ring gear with shim(s). Calculate the 
respective thicknesses from information 
marked on the final gear case, ring gear bear-
ing housing, and ring gear.
T R..  Bearing holder bolt
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
LOCTITE ®
New
a. 34.5–35.5 mm (1.36 –1.40 in)
a
ab A
1
2
c
ef Bd    
						

							
haha SHAFT DRIVE
4-114
b. To find final drive pinion gear shim thickness  “A” , use the following formula:
Where:
a = 85.00
b = a numeral on the final gear case, to be di-
vided by 100 and added to “ 84”.
Example:
If the final gear case is marked  “52”:
Round off to the hundredths digit and select 
the appropriate shim(s).
TIP
In the example above, the calculated final drive 
pinion gear shim thickness is 0.28 mm (0.011 
in). The chart instructs you to round off the 8 to 
10. Thus, you should use a 0.30 mm (0.012 in) 
final drive pinion gear shim.
Shim sizes are supplied in the following thick-
nesses.
c. To find ring gear shim thickness  “B”, use the 
following formula: Where:
c = a numeral on the final gear case, to be di-
vided by 100 and added to “
52”.
d = a numeral indicated by the punch mark on 
the ring gear bearing housing, to be divided 
by 100 and added to  “1”.
e = a numeral (positive or negative) on the in-
side of the ring gear, to be divided by 100 and 
added to  “38.50”.
f = the bearing thickness constant.Example:
If the final drive housing is marked  “97” , the 
ring gear bearing housing is marked  “03” , the 
ring gear is marked  “- 08 ”, and “f”  is 13.00:
Round off the hundredths digit and select ap-
propriate shim(s).
Final drive pinion gear shim thickness
A = a - b - 0.2
A = 85.00 - (84 + 52/100) - 0.2 = 85.00 - (84 + 0.52) - 0.2
= 85.00 - 84.52 - 0.2
=0.28
Hundredth Rounded value 0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
 Final drive pinion gear shims
Thickness (mm)0.15 0.30 0.40 0.45 0.50 0.60
Ring gear shim thickness
B = c - d - e - f
52
97
b
  Bearing thickness
13.00 mm (0.51 in)
B = (52 + 97/100) - (1 + 03/100) -  (38.50 - 08/100) - 13.00
= (52 + 0.97) - (1 + 0.03) -  (38.50 - 0.08) - 13.00
= 52.97 - 1.03 - 38.42 - 13.00
=0.52
02
0 1
03
04
05
52
97
c
d
e  
						

							
haha SHAFT DRIVE
4-115
TIP
In the example above, the calculated ring gear 
shim thickness is 0.52 mm (0.0205 in). The chart 
instructs you to round off the 2 to 0. Thus, you 
should use a 0.50 mm (0.0197 in) ring gear 
shim. Shim sizes are supplied in the following thick-
nesses.
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2. Install: Shims (as calculated)
 Final drive pinion gear
 Bearing retainer
(with the bearing retainer wrench “1”)
NOTICE
ECA14350
The bearing retainer has left-hand threads. 
To tighten the bearing retainer, turn it coun-
terclockwise.
3. Install:
Coupling gear “1”
 Washer  “2”
TIP
Install the washer with its  “OUT”  mark “a”  facing 
outward.
4. Install:
Coupling gear nut 
(with the coupling gear holding tool “1”)
5. Stake the coupling gear nut “1”  at a cutout “a” 
in the final drive pinion gear.
6. Install: Oil seal  “1” 
Hundredth Rounded value
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
  Ring gear shims
Thickness (mm)0.25 0.30 0.40 0.50
T R..  Bearing retainer
130 Nm (13 m· kgf, 94 ft·lbf)
  Bearing retainer wrench
90890-01561
YM-01561
1
T R..  Coupling gear nut
150 Nm (15 m· kgf, 108 ft·lbf)
LOCTITE ®
  Coupling gear holding tool
90890-01560
YM-01560
1
2
a
New
1
1
a
New  
						

							
haha SHAFT DRIVE
4-116
7. Install: Ring gear bearing housing
(along with the ring gear)
8. Adjust: Final gear backlash
Refer to  “MEASURING THE FINAL GEAR 
BACKLASH ” on page 4-108 and  “ADJUST-
ING THE FINAL GEAR BACKLASH ” on 
page 4-109.
9. Measure:
Ring-gear-to-thrust-washer clearance
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a. Remove the ring gear bearing housing (along 
with the ring gear).
b. Place four pieces of Plastigauge ® between 
the original thrust washer and the ring gear.
c. Install the ring gear bearing housing and  tighten the bolts  “1” and bolts  “2” to specifica-
tion.
TIP
Do not turn the final drive pinion gear and ring 
gear while measuring the ring-gear-to-thrust-
washer clearance with Plastigauge ®.d. Remove the ring gear bearing housing.
e. Measure the width of the flattened Plasti-
gauge® “1”.
f. If the ring-gear-to-thrust-washer clearance is  within specification, install the ring gear bear-
ing housing (along with the ring gear).
g. If the ring-gear-to-thrust-washer clearance is  out of specification, select the correct thrust 
washer as follows.
h. Select the suitable thrust washer from the fol- lowing chart.
i. Repeat the measurement steps until the ring- gear-to-thrust-washer clearance is within the 
specified limits.▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS23650
CHECKING THE DRIVE SHAFT
1. Check: Drive shaft splines
Damage/wear   Replace the drive shaft.
 Installed depth 
“a”
6.0– 6.5 mm (0.24– 0.26 in)
T R.. Ring gear bearing housing bolt 
(M10) 
“1”
40 Nm (4.0 m· kgf, 29 ft·lbf)
Ring gear bearing housing bolt 
(M8)  “2”
23 Nm (2.3 m· kgf, 17 ft·lbf)
1
aNew
  Ring-gear-to-thrust-washer clear-
ance
0.10– 0.20 mm (0.004 –0.008 in)
  Thrust washer
Thickness (mm)1.2 1.4 1.6 1.8 2.0
2
2 2
2
1
12
2
1  
						

							
haha SHAFT DRIVE
4-117
EAS23660
INSTALLING THE DRIVE SHAFT AND FINAL 
DRIVE ASSEMBLY
1. Lubricate: Drive shaft spline (final drive pinion gear side)
2. Lubricate: Drive shaft spline (universal joint side)
3. Install: Oil seal  “1” 
 Washer  “2”
(to the drive shaft with the fork seal driver 
weight  “3” and fork seal driver attachment (ø 
30) “4”)
4. Install: Circlips  5. Install:
Drive shaft assembly  “1”
(to the final gear case with the fork seal driver 
weight “2”  and fork seal driver attachment 
(ø 38) “3”)
6. Install: Final drive assembly
TIP
Align the drive shaft splines with the driven yoke 
of the universal joint.
7. Tighten:
Final drive assembly nuts
  Recommended lubricant
Molybdenum disulfide grease
  Recommended lubricant
Lithium-soap-based grease
  Fork seal driver weight
90890-01367
Replacement hammer YM-A9409-7
Fork seal driver attachment ( ø30)
90890-01400
Replacement 31 mm YM-A94093
New
3
4
2
1
New
New
  Fork seal driver weight
90890-01367
Replacement hammer YM-A9409-7
Fork seal driver attachment ( ø38)
90890-01372
Replacement 38 mm YM-A5142-1
  Installed depth “a”
8.5– 10.0 mm (0.33– 0.39 in)
4. Oil seal
T R..  Final drive assembly nut
42 Nm (4.2 m ·kgf, 30 ft· lbf)
2
3 1
a
4