2012 Na Yamaha Super Tenere Manual

							
haha CAMSHAFTS
5-16
9. Remove: Cylinder head cover  “1”
 Cylinder head cover gasket
TIP
Lift up the wire harness, brake pipes, clutch pipe, 
and clutch hose, and then pull the cylinder head 
cover rearward to remove it.
EAS23810
REMOVING THE CAMSHAFTS
1. Align:
“ K”  mark  “a” on the pickup rotor
(with the crankcase mating surface  “b”)
▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Turn the crankshaft clockwise.
b. Align the “K”  mark “a” with the crankcase mat-
ing surface “b”.
TIP
When the “K”  mark “a” is aligned with the crank-
case mating surface “b” , check that the match 
mark “c”  on the intake camshaft sprocket and 
match mark  “d” on the exhaust camshaft sprock-
et are aligned with the cylinder head surface  “e”. 
Also, check that the hole  “f” in the intake cam-
shaft is aligned with the match mark  “g” on the 
intake camshaft cap. If the match marks or hole 
are not aligned, turn the crankshaft clockwise 
360 degrees.
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2. Remove: Timing chain tensioner “1”
 Timing chain tensioner gasket
3. Remove: Camshaft caps
NOTICE
ECA13720
To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
1
2 3
1
a b
ec
de
fg
1  
						

							
haha CAMSHAFTS
5-17
4. Remove: Intake camshaft  “1”
 Exhaust camshaft  “2”
TIP
To prevent the timing chain from falling into the 
crankcase, fasten it with a wire  “3”.
5. Remove: Intake camshaft sprocket  “1”
 Exhaust camshaft sprocket “2”
TIP
While holding the intake camshaft sprocket and 
exhaust camshaft sprocket with the rotor holding 
tool “3” , loosen the intake camshaft sprocket 
bolts and exhaust camshaft sprocket bolts. EAS23850
CHECKING THE CAMSHAFTS
1. Check:
Camshaft lobes
Blue discoloration/pitting/scratches   Re-
place the camshaft.
2. Measure: Camshaft lobe dimensions  “a” and “b”
Out of specification   Replace the camshaft.
3. Measure: Camshaft runout
Out of specification   Replace.
  Rotor holding tool
90890-01235
Universal magneto & rotor holder YU-01235
1
2
3
31
2
3
  Camshaft lobe dimensions
Intake A40.250– 40.350 mm (1.5846 –
1.5886 in)
Limit 40.150 mm (1.5807 in)
Intake B 29.976– 30.076 mm (1.1802 –
1.1841 in)
Limit 29.876 mm (1.1762 in)
Exhaust A 39.250– 39.350 mm (1.5453 –
1.5492 in)
Limit 39.150 mm (1.5413 in)
Exhaust B 29.950– 30.050 mm (1.1791 –
1.1831 in)
Limit 29.850 mm (1.1752 in)    
						

							
haha CAMSHAFTS
5-18
4. Measure: Camshaft-journal-to-camshaft-cap clearance
Out of specification   Measure the camshaft 
journal diameter.
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a. Install the camshaft into the cylinder head 
(without the camshaft caps).
b. Position a strip of Plastigauge ® “1” onto the 
camshaft journal as shown.
c. Install the camshaft caps.
TIP
 Tighten the camshaft cap bolts in stages and in 
a crisscross pattern, working from the inner 
caps out.
 Do not turn the camshaft when measuring the 
camshaft journal-to-camshaft cap clearance 
with the Plastigauge®.
d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “1”.
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5. Measure: Camshaft journal diameter  “a”
Out of specification   Replace the camshaft.
Within specification   Replace the cylinder 
head and the camshaft caps as a set.
EAS23P1090
CHECKING THE CAMSHAFT SPROCKET
1. Check: Camshaft sprocket
More than 1/4 tooth wear  “a”  Replace the 
camshaft sprocket, timing chain, and crank-
shaft as a set.
  Camshaft runout limit
0.030 mm (0.0012 in)
  Camshaft-journal-to-camshaft-
cap clearance
0.028 –0.062 mm (0.0011– 0.0024 
in)
T R..  Camshaft cap bolt
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
1
  Camshaft journal diameter
24.459– 24.472 mm (0.9630 –
0.9635 in)
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
1    
						

							
haha CAMSHAFTS
5-19
EAS23960
CHECKING THE TIMING CHAIN 
TENSIONERS
1. Check: Timing chain tensioner
Cracks/damage   Replace.
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a. Push and insert timing chain tensioner rod  “1” 
into the timing chain tensioner housing.
TIP
Push the timing chain tensioner rod in direction 
“a” , and turn the timing chain tensioner body  “2” 
in direction “b” until it stops.
b. Keep pressing the timing chain tensioner rod,  mount clip “3”  into groove “4”, and lock the 
timing chain tensioner rod.
c. Push the timing chain tensioner rod in direc- tion  “c”.
d. Make sure that the timing chain tensioner rod  can smoothly move out from the timing chain 
tensioner housing in direction  “d”. If not 
smooth, replace the timing chain tensioner 
assembly.
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EAS23980
CHECKING THE DECOMPRESSION SYSTEM
1. Check: Decompression system
TIP
Check that the decompression pins  “1” 
projects from the camshaft. 
Check that the decompression cams  “2” and 
decompression pins  “1” moves smoothly.
EAS24000
INSTALLING THE CAMSHAFTS
1. Align: “ K”  mark  “a” on the pickup rotor
(with the crankcase mating surface  “b”)
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a. Turn the crankshaft clockwise.
b. Align the “K”  mark “a” with the crankcase mat-
ing surface  “b”.
TIP
When piston #1 is before 71 ° of TDC on the 
compression stroke, align the  “K” mark with the 
crankcase mating surface.
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2. Install: Decompressor lever pins  “1”
 Decompressor lever #1  “2”
 Decompressor lever #2  “3”
TIP
Face the cutout  “a” in each decompressor le-
ver pin toward the exhaust camshaft sprocket.
 Install the decompressor lever pins, decom-
pressor lever #1, and decompressor lever #2 in 
the exhaust camshaft as shown in the illustra-
tion.
a
b
2
1
1
2
2
ab  
						

							
haha CAMSHAFTS
5-20
3. Install: Intake camshaft sprocket  “1”
 Exhaust camshaft sprocket “2”
NOTICE
ECA23P1077
Be sure to tighten the camshaft sprocket 
bolts to the specified torque to avoid the 
possibility of the bolts coming loose and 
damaging the engine.
TIP
Install the cam lobe #1  “a” at the position 
shown in the illustration. 
 Tighten the camshaft sprocket bolt with the ro-
tor holding tool  “3”.  4. Install:
Timing chain “1”
 Exhaust camshaft  “2”
 Exhaust camshaft cap
NOTICE
ECA23P1073
Do not turn the crankshaft when installing 
the camshaft to avoid damage or improper 
valve timing.
TIP
When installing the timing chain, start with the 
exhaust camshaft and be sure to keep the tim-
ing chain as tight as possible on the exhaust 
side.
 Make sure the match mark  “a” on the exhaust 
camshaft sprocket are aligned with the cylinder 
head edge.
T R..  Camshaft sprocket bolt
24 Nm (2.4 m· kgf, 17 ft·lbf)
  Rotor holding tool
90890-01235
Universal magneto & rotor holder YU-01235
3
11
a
2
a
3
3
11
T R..  Exhaust camshaft cap bolt
10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
a21
a
31
2
3  
						

							
haha CAMSHAFTS
5-21
5. Install: Timing chain “1”
 Intake camshaft  “2”
 Intake camshaft caps
NOTICE
ECA23P1073
Do not turn the crankshaft when installing 
the camshaft to avoid damage or improper 
valve timing.
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a. Install the timing chain onto intake camshaft 
sprocket, and then install the intake camshaft 
onto the cylinder head.
TIP
Make sure the match mark “a”  on the intake 
camshaft sprocket are aligned with the cylinder 
head edge.
 Make sure that the distance between the “E” 
mark  “b” on the exhaust camshaft sprocket and 
the  “I” mark “c”  on the intake camshaft sprocket 
is 4.5 timing chain links  “d” as shown in the il-
lustration. b. Install the intake camshaft caps and then fin-
ger tighten the intake camshaft cap bolts.
TIP
Make sure each camshaft cap is installed in its 
original place. Refer to the identification marks 
as follows:
“1” : Left intake camshaft cap
“2” : Center intake camshaft cap
 Make sure the arrow mark  “e” on each intake 
camshaft cap points towards the right side of 
the engine. 
c. Fasten the timing chain securely to the intake  camshaft sprocket  “3” with a plastic locking 
tie  “4”.
d. Tighten the intake camshaft cap bolts.
TIP
To prevent the timing chain from skipping a tooth 
on the intake camshaft sprocket, do not remove 
the plastic locking tie before installing the timing 
chain tensioner.
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6. Install: Timing chain tensioner
 Timing chain tensioner gasket 
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a. Push and insert timing chain tensioner rod “1” 
into the timing chain tensioner housing.
a1
2
a1
2
1
dc
bT R..  Intake camshaft cap bolt
10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
e
e
4
3
New  
						

							
haha CAMSHAFTS
5-22
TIP
Push the timing chain tensioner rod in direction 
“a” , and turn the timing chain tensioner body  “2” 
in direction “a” until it stops.
b. Keep pressing the timing chain tensioner rod,  mount clip “3”  into groove “4”, and lock the 
timing chain tensioner rod.
c. Install the timing chain tensioner in the cylin- der block.
d. Push the timing chain guide  “5” as shown in 
the illustration to release the timing chain ten-
sioner rod.
e. Check that the timing chain is taut. If the  chain is slack, reinstall the timing chain ten-
sioner.
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7. Remove: Plastic locking tie
TIP
Remove the plastic locking tie that was used to 
fasten the timing chain to the intake camshaft 
sprocket.
8. Turn:
Crankshaft
(several turns clockwise)
9. Check: “ K”  mark
Make sure the  “K” mark  “a” on the pickup ro-
tor is aligned with the crankcase mating sur-
face  “b”.
 Camshaft sprocket match mark
Make sure the match marks  “c” on the cam-
shaft sprockets are aligned with the cylinder 
head mating surface “d”.
Out of alignment   Adjust.
Refer to the installation steps above.
 Intake camshaft hole
Make sure the hole  “e” in the intake camshaft 
is aligned with the match mark  “f” on the in-
take camshaft cap.
Out of alignment   Adjust.
Refer to the installation steps above.
T R..  Timing chain tensioner bolt
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
a 1
2
4
3
5
a b
dc
cd  
						

							
haha CAMSHAFTS
5-23
10.Measure: Valve clearance
Out of specification   Adjust.
Refer to  “ADJUSTING THE VALVE CLEAR-
ANCE”  on page 3-5.
EAS23P1091
INSTALLING THE CYLINDER HEAD COVER
1. Install: Cylinder head cover gasket  “1” 
(to the cylinder head cover  “2”)
TIP
Apply Three Bond No.1541C ® “3” onto the 
mating surfaces of the cylinder head cover and 
cylinder head cover gaskets.
 Apply Yamaha bond No.1215  “4” onto the mat-
ing surfaces of the cylinder head cover gasket 
and cylinder head.
 Install a cylinder head cover gasket  “1”, and 
then cut the portions  “a”.
2. Install: Cylinder head cover
NOTICE
ECA23P1074
When installing the cylinder head cover to 
the cylinder head, make sure that the cylin-
der head cover gasket remains in place. 3. Check:
Cylinder head cover gasket
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a. Remove the electrical components tray bolts.
b. Move the electrical components tray  “1” away 
from the engine as shown in the illustration. 
c. Check that the cylinder head cover gasket  “2” 
is installed properly between the cylinder 
head cover and the cylinder head.
d. Install the electrical components tray bolts. Refer to “ GENERAL CHASSIS ” on page 4-1.
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4. Tighten: Cylinder head cover bolts
TIP
Tighten the cylinder head cover bolts in stages 
and in a crisscross pattern.
  Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
ef
New
a
4
3
a
1
2New
T R.. Cylinder head cover bolt
10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
1
22  
						

							
haha CAMSHAFTS
5-24
5. Install: Brake pipe (hydraulic unit to left front brake 
caliper)
 Brake pipe (front brake master cylinder to hy-
draulic unit)
 Clutch pipe
6. Install: Brake hose holders  “1”
TIP
Be sure to fit the projection  “a” on the outer sec-
tion of the brake hose holder into the hole “b”  in 
the inner section.
7. Install:
Clutch hose holder bolt  “1”
TIP
Insert the tab “a” on the clutch hose holder into 
the slot “b” in the frame.
8. Install: Brake hose joint bolt (hydraulic unit to left 
front brake caliper)  “1”
 Brake hose joint bolt (front brake master cyl-
inder to hydraulic unit)  “2”
TIP
Make sure that the tab  “a” on the brake hose 
joint bracket contacts the side of the brake hose 
joint  “b”.
9. Install: Stator coil lead
 Starter motor lead
 Plastic bands
 Wire harness holder
T R..  Brake hose holder bolt
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
T R.. Clutch hose holder bolt
9 Nm (0.9 m ·kgf, 6.5 ft· lbf)
1
1
ab
ba
1
T R.. 
Brake hose joint bolt (hydraulic 
unit to left front brake caliper)
7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
Brake hose joint bolt (front brake 
master cylinder to hydraulic unit) 9 Nm (0.9 m ·kgf, 6.5 ft· lbf)
ba
1
ab2  
						

							
haha CYLINDER HEAD
5-25
EAS24100
CYLINDER HEAD Removing the cylinder head
Order Job/Parts to remove Q ’ty Remarks
TIP
Place a suitable stand under the engine.
Exhaust pipe/Muffler Refer to “ENGINE REMOVAL ” on page 5-3.
Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-11.
Thermostat/Coolant temperature sensor Refer to “THERMOSTAT ” on page 6-4.
1 Engine mounting bolt (front side) 4
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Timing chain guide (exhaust side) 1
For installation, reverse the removal proce-
dure.
5
2
3 4
1
4
1
1
LT
LT
New
NewNew
New
New
EE
E
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
28 Nm (2.8 m 
kgf, 20 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.
75 Nm (7.5 m 
kgf, 54 ft 
Ibf)T.R.
75 Nm (7.5 m 
kgf, 54 ft 
Ibf)T.R.
75 Nm (7.5 m 
kgf, 54 ft 
Ibf)T.R.
1st
2nd
Final
T.R .
Specified angle 215–22520 Nm (2.0 m

kgf, 14 ft 
Ibf)
30 Nm (3.0 m 
kgf, 22 ft 
Ibf)
1st
2nd
Final 30 Nm (3.0 m

kgf, 22 ft 
Ibf)
T.R.
Specified angle 180–190 20 Nm (2.0 m 
kgf, 14 ft 
Ibf)