2012 Na Yamaha Super Tenere Manual

							
haha CYLINDER AND PISTONS
5-36
EAS24370
CYLINDER AND PISTONS Removing the cylinder and pistons
Order Job/Parts to remove Q ’ty Remarks
Cylinder head Refer to “CYLINDER HEAD ” on page 5-25.
1 Water jacket cover 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 4
6 Piston pin 2
7Piston 2
8Top  ring 2
9 2nd ring 2
10 Oil ring 2
For installation, reverse the removal proce-
dure.
5
5
6
7
8
9
10
4
4
2
3
1
LTLT
E
E
New
New
E
New
LS
LS
New
E
New
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.  
						

							
haha CYLINDER AND PISTONS
5-37
EAS24380
REMOVING THE PISTONS
The following procedure applies to both of the 
pistons.
1. Remove: Piston pin clips  “1”
 Piston pin  “2”
 Piston  “3”
NOTICE
ECA13810
Do not use a hammer to drive the piston pin 
out.
TIP
Before removing the piston pin clips, cover the 
crankcase opening with a clean rag to prevent 
the piston pin clips from falling into the crank-
case.
 For reference during installation, put an identi-
fication mark on each piston crown.
 Before removing the piston pin, deburr the pis-
ton pin clip grooves and the piston pin bore ar-
ea. If both areas are deburred and the piston 
pin is still difficult to remove, remove it with the 
piston pin puller set “4”.
2. Remove: Top ring
 2nd ring 
Oil ring
TIP
When removing a piston ring, open the end gap 
with your fingers and lift the other side of the ring 
over the piston crown.
EAS24390
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to both of the 
cylinders and pistons.
1. Check:
Piston wall
 Cylinder wall
Vertical scratches   Rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
2. Measure: Piston-to-cylinder clearance
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Measure cylinder bore  “C” with the cylinder 
bore gauge.
TIP
Measure cylinder bore  “C” by taking side-to-side 
and front-to-back measurements of the cylinder. 
Then, find the average of the measurements.
  Piston pin puller set
90890-01304
Piston pin puller YU-01304
1
3
2
  Bore
98.000– 98.010 mm (3.8583 –
3.8587 in)
Taper limit 0.05 mm (0.002 in)
Out of round limit 0.05 mm (0.002 in)
Cylinder bore “C” = maximum of D 1–D
6
Taper limit  “T” = maximum of D
1 or D
2 - max-
imum of D 5 or D
6
Out of round limit “R” = maximum of D 1, D
3 or 
D 5 - minimum of D
2, D
4 or D
6   
						

							
haha CYLINDER AND PISTONS
5-38
b. If out of specification, replace the cylinder,  and replace the piston and piston rings as a 
set.
c. Measure piston skirt diameter D  “a” with the 
micrometer.
d. If out of specification, replace the piston and  piston rings as a set.
e. Calculate the piston-to-cylinder clearance 
with the following formula.
f. If out of specification, replace the cylinder,  and replace the piston and piston rings as a 
set.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲EAS24430
CHECKING THE PISTON RINGS
The following procedure applies to both of the 
piston rings.
1. Measure:
Piston ring side clearance
Out of specification   Replace the piston 
and piston rings as a set.
TIP
Before measuring the piston ring side clearance, 
eliminate any carbon deposits from the piston 
ring grooves and piston rings.
2. Install: Piston ring
(into the cylinder)
TIP
Level the piston ring into the cylinder with the 
piston crown.
  Diameter D
97.965– 97.980 mm (3.8569–
3.8575 in)
b. 8.0 mm (0.31 in) from the bottom edge of the  piston
 Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter  “D”
 Piston-to-cylinder clearance
0.020 –0.045 mm (0.0008– 0.0018 
in)
Limit 0.15 mm (0.0059 in)
  Piston ring
Top ringRing side clearance0.030– 0.070 mm (0.0012 –
0.0028 in)
Limit 0.120 mm (0.0047 in)
2nd ring Ring side clearance0.020– 0.060 mm (0.0008 –
0.0024 in)
Limit 0.120 mm (0.0047 in)     
						

							
haha CYLINDER AND PISTONS
5-39
3. Measure: Piston ring end gap
Out of specification   Replace the piston 
ring.
TIP
The oil ring expander spacer ’s end gap cannot 
be measured. If the oil ring rail ’s gap is exces-
sive, replace all three piston rings.
EAS24440
CHECKING THE PISTON PINS
The following procedure applies to both of the 
piston pins.
1. Check:
Piston pin
Blue discoloration/grooves   Replace the 
piston pin and then check the lubrication sys-
tem.
2. Measure:
Piston pin outside diameter “a”
Out of specification   Replace the piston pin. 3. Measure:
Piston pin bore diameter  “b”
Out of specification   Replace the piston.
4. Calculate: Piston-pin-to-piston-pin-bore clearance
Out of specification   Replace the piston pin 
and piston as a set.
EAS24470
INSTALLING THE PISTONS AND CYLINDER
The following procedure applies to both of the 
pistons.
a. 40.0 mm (1.57 in)
 
Piston ring
Top ringEnd gap (installed)0.20– 0.35 mm (0.0079– 0.0138 
in)
2nd ring Limit0.60 mm (0.0236 in)
End gap (installed) 0.35– 0.50 mm (0.0138– 0.0197 
in)
Limit 0.85 mm (0.0335 in)
Oil ring End gap (installed)0.20– 0.70 mm (0.0079– 0.0276 
in)
  Piston pin outside diameter
21.991– 22.000 mm (0.8658 –
0.8661 in)
Limit 21.971 mm (0.8650 in)
  Piston pin bore inside diameter
22.004– 22.015 mm (0.8663 –
0.8667 in)
Limit 22.045 mm (0.8679 in)
 Piston-pin-to-piston-pin-bore clearance =
Piston pin bore inside diameter  “b” -
Piston pin outside diameter “a”
  Piston-pin-to-piston-pin-bore 
clearance
0.004 –0.024 mm (0.00016 –
0.00094 in)     
						

							
haha CYLINDER AND PISTONS
5-40
1. Install: Oil ring expander “1”
 Lower oil ring rail  “2”
 Upper oil ring rail  “3”
 2nd ring “4”
 Top ring “5”
TIP
Install the oil ring expander as shown in the il-
lustration.
 Be sure to install the piston rings so that the 
manufacturer marks face up.
2. Install: Piston  “1”
 Piston pin  “2”
 Piston pin clips  “3” 
TIP
Apply engine oil onto the piston pin.
 Make sure the punch mark  “a” on the piston 
points towards the exhaust side of the engine.
 Before installing the piston pin clips, cover the 
crankcase opening with a clean rag to prevent 
the piston pin clips from falling into the crank-
case.
 Install the piston pin clips so that the clip ends 
are 3 mm (0.12 in)  “b” or more from the cutout 
in the piston.
 Reinstall each piston into its original cylinder 
(numbering order starting from the left: #1 to 
#2). 3. Lubricate:
Piston
 Piston rings
 Cylinder
(with the recommended lubricant)
4. Offset: Piston ring end gaps
5. Install: Dowel pins
 Cylinder gasket 
6. Install: Cylinder  “1”
TIP
While compressing the piston rings, install the 
cylinder.
 Pass the timing chain and timing chain guide 
(intake side) through the timing chain cavity.
5
4
3
1
2
New
12
3
a
New
  Recommended lubricant
Engine oil
a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
f. 40 mm (1.57 in)
A. Exhaust side
b
2
1
New
3
120
120 120
e
b
c
d ff a
A
New  
						

							
haha CYLINDER AND PISTONS
5-41
1  
						

							
haha GENERATOR AND STARTER CLUTCH5-42
EAS24480
GENERATOR AND STARTER CLUTCHRemoving the stator coil, generator rotor and starter clutch
Order Job/Parts to remove Q ’ty Remarks
Engine oil Drain.
Refer to 
“CHANGING THE ENGINE OIL ” on 
page 3-24.
Side cowlings Refer to 
“GENERAL CHASSIS ” on page 
4-1.
Engine guard Refer to “ENGINE REMOVAL ” on page 5-3.
Fuel tank Refer to “FUEL TANK ” on page 7-1.
1 Stator coil coupler 1 Disconnect.
2 Engine guard bracket 1
3 Holder (fuel tank overflow hose and fuel tank 
breather hose) 1
4 Holder (sidestand switch lead and oil level 
switch lead) 1
5 Generator cover 1
6 Generator cover gasket 1
LT
LT
E
LT
E
E
LTLT
E
E
E
LTLTNew
45
(3)
(8)
3
2
6
1
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
12 Nm (1.2 m 
kgf, 8.7 ft 
Ibf)T.R.
12 Nm (1.2 m 
kgf, 8.7 ft 
Ibf)T.R.
32 Nm (3.2 m 
kgf, 23 ft 
Ibf)T.R.
130 Nm (13 m 
kgf, 94 ft 
lbf)T.R.
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.  
						

							
haha GENERATOR AND STARTER CLUTCH5-43
Removing the stator coil, generator rotor and starter clutchOrder Job/Parts to remove Q ’ty Remarks
7 Dowel pin 2
8 Stator coil lead holder 1
9 Stator coil 1
10 Generator rotor 1
11 Woodruff key 1
12 Starter clutch idle gear shaft 1
13 Starter clutch idle gear 1
14 Torque limiter 1
15 Starter clutch gear 1
16 Starter clutch 1
17 Washer 1
For installation, reverse the removal proce-
dure.
LT
LT
E
LT
E
E
LTLT
E
E
E
LTLT
14
13
12
15
16
17
(3)
(8)
10
11
7 7
9
8
10 Nm (1.0 m

kgf, 7.2 ft 
Ibf)T.R.
12 Nm (1.2 m 
kgf, 8.7 ft 
Ibf)T.R.
12 Nm (1.2 m 
kgf, 8.7 ft 
Ibf)T.R.
32 Nm (3.2 m 
kgf, 23 ft 
Ibf)T.R.
130 Nm (13 m 
kgf, 94 ft 
lbf)T.R.
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.  
						

							
haha GENERATOR AND STARTER CLUTCH5-44
EAS24490
REMOVING THE GENERATOR
1. Remove:Generator rotor bolt  “1”
 Washer
TIP
While holding the generator rotor “2”  with the 
sheave holder “3” , loosen the generator rotor 
bolt.
2. Remove:
Generator rotor  “1”
(with the flywheel puller  “2”)
 Woodruff key
NOTICE
ECA13880
To protect the end of the crankshaft, place an 
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.
TIP
Install the flywheel puller bolts to the threaded 
holes of the starter clutch.
 Make sure the flywheel puller is centered over 
the generator rotor. EAS24560
REMOVING THE STARTER CLUTCH
1. Remove:
Starter clutch bolts
 Starter clutch
TIP
While holding the generator rotor  “1” with the 
sheave holder  “2”, loosen the starter clutch 
bolts.
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
Starter clutch rollers
Damage/wear   Replace.
2. Check:
Starter clutch idle gear
 Starter clutch gear
Burrs/chips/roughness/wear   Replace the 
defective part(s).
3. Check: Starter clutch gear contact surfaces
Damage/pitting/wear   Replace the starter 
clutch gear.
4. Check:
 Starter clutch operation
  Sheave holder
90890-01701
Primary clutch holder YS-01880-A
  Flywheel puller
90890-01362
Heavy duty puller YU-33270-B
3 12
 
Sheave holder
90890-01701
Primary clutch holder YS-01880-A
1 2
12  
						

							
haha GENERATOR AND STARTER CLUTCH5-45
▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Install the starter clutch gear  “1” onto the gen-
erator rotor  “2” and hold the generator rotor.
b. When turning the starter clutch gear clock- wise “A” , the starter clutch and the starter 
clutch gear should engage, otherwise the 
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter-
clockwise  “B”, it should turn freely, otherwise 
the starter clutch is faulty and must be re-
placed.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲
EAS3D81022
CHECKING THE TORQUE LIMITER
1. Check: Torque limiter
Damage/wear   Replace.
TIP
Do not disassemble the torque limiter.
EAS24600
INSTALLING THE STARTER CLUTCH
1. Install:
Starter clutch  “1”
 Washer  “2”
TIP
Install the starter clutch so that the side of the 
starter clutch roller assembly with the arrow 
mark  “a” is toward the generator rotor  “3”.
 While holding the generator rotor with the 
sheave holder  “4”, tighten the starter clutch 
bolts. EAS24500
INSTALLING THE GENERATOR
1. Install:
Woodruff key
 Generator rotor
 Washer
 Generator rotor bolt
TIP
Clean the tapered portion of the crankshaft and 
the generator rotor hub.
 When installing the generator rotor, make sure 
the woodruff key is properly seated in the key-
way of the crankshaft.
 Lubricate the generator rotor bolt threads and 
washer mating surfaces with engine oil.
2. Tighten: Generator rotor bolt  “1”
TIP
While holding the generator rotor  “2” with the 
sheave holder  “3”, tighten the generator rotor 
bolt.
T R..  Starter clutch bolt
32 Nm (3.2 m· kgf, 23 ft·lbf)
LOCTITE ®
  Sheave holder
90890-01701
Primary clutch holder YS-01880-A
1
A
B
2
T R..  Generator rotor bolt
130 Nm (13 m· kgf, 94 ft·lbf)
  Sheave holder
90890-01701
Primary clutch holder YS-01880-A
1 a
3
2
34