2012 Na Yamaha Super Tenere Manual
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haha GENERATOR AND STARTER CLUTCH5-46 3. Apply:Sealant (onto the stator coil lead grommet) 4. Install: Generator cover gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern. 5. Connect: Stator coil coupler TIP To route the stator coil lead, refer to “CABLE ROUTING ” on page 2-43. Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) T R.. Generator cover bolt (M6 × 55) 12 Nm (1.2 m· kgf, 8.7 ft·lbf) LOCTITE ® Generator cover bolt (M6 × 25) 12 Nm (1.2 m· kgf, 8.7 ft·lbf) 3 12 New
haha ELECTRIC STARTER 5-47 EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q ’ty Remarks Fuel tank Refer to “FUEL TANK ” on page 7-1. 1 Starter motor lead 1 Disconnect. 2 Starter motor assembly 1 For installation, reverse the removal proce- dure. 1 2 12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R. 5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R. NewLS
haha ELECTRIC STARTER 5-48 Disassembling the starter motor Order Job/Parts to remove Q ’ty Remarks 1 Starter motor front cover 1 2 Starter motor rear cover 1 3 Brush holder set 1 4 Armature assembly 1 5 Starter motor yoke 1 For assembly, reverse the disassembly pro- cedure. 1 4 2 3 (4) 5 5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R. 11 Nm (1.1 m kgf, 8.0 ft Ibf)T.R. New New
haha ELECTRIC STARTER 5-49 EAS24790 CHECKING THE STARTER MOTOR 1. Check: Commutator Dirt Clean with 600 grit sandpaper. 2. Measure: Mica undercut “a” Out of specification Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. TIP The mica of the commutator must be undercut to ensure proper operation of the commutator. 3. Measure: Armature assembly resistances (commutator and insulation) Out of specification Replace the starter motor. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Measure the armature assembly resistances with the digital circuit tester. b. If any resistance is out of specification, re- place the starter motor. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 4. Measure: Brush length “a” Out of specification Replace the brush holder set. 5. Measure: Brush spring force Out of specification Replace the brush holder set. 6. Check: Gear teeth Damage/wear Replace the starter motor. Mica undercut (depth) 0.70 mm (0.03 in) Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 Armature coil Commutator resistance “1” Continuity (0.010 –0.020 at 20 ° C (68 ° F)) Insulation resistance “2” No continuity (Above 1 M at 20 ° C (68 ° F)) a Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.02– 6.51 N (614 –664 gf, 21.69 – 23.45 oz) M 1 2 a
haha ELECTRIC STARTER 5-50 7. Check: Bearing Oil seal Damage/wear Replace the starter motor front cover. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: Starter motor yoke “1” Starter motor front cover “2” Starter motor rear cover “3” TIP Align the match marks “a” on the starter motor yoke with the match marks “b” on the starter mo- tor front and rear covers. a a bb 213
haha CLUTCH 5-51 EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q ’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL ” on page 3-24. 1 Engine oil filler cap 1 2 Crankshaft end accessing screw 1 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Clutch cover damper plate 1 7 Clutch cover damper 1 For installation, reverse the removal proce- dure. 2 3 (14) 1 NewNew New 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. 15 Nm (1.5 m kgf, 11 ft Ibf)T.R. LS LSNew 4 7 6 5 (4) 5 LTLT
haha CLUTCH 5-52 Removing the clutch Order Job/Parts to remove Q ’ty Remarks Clutch release cylinder Refer to “Removing the clutch release cylin- der ”. 1 Clutch spring plate retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Bearing 1 6 Short clutch push rod 1 7Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter: 124 mm (4.88 in) 10 Clutch plate 7 11 Friction plate 2 7 Inside diameter: 124 mm (4.88 in) 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. 125 Nm (12.5 m kgf, 90 ft lbf)T.R.New E E E E E LS LS E 2 9 11 9,11 10 34 65 7 1 (6) 8
haha CLUTCH 5-53 Removing the clutch Order Job/Parts to remove Q ’ty Remarks 12 Clutch boss nut 1 13 Conical spring washer 1 14 Wire circlip 1 15 Clutch plate 1 16 Friction plate 3 1 Inside diameter: 135 mm (5.31 in) 17 Clutch damper spring 1 18 Clutch damper spring seat 1 19 Clutch boss 1 20 Thrust washer 1 21 Clutch housing 1 22 Spacer 1 23 Bearing 1 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. 125 Nm (12.5 m kgf, 90 ft lbf)T.R.New New NewE E E E E LS LS E 14 12 15 16 17 21 18 19 202223 13 16 (6)
haha CLUTCH 5-54 Removing the clutch Order Job/Parts to remove Q ’ty Remarks 24 Spacer 1 25 Thrust plate 1 For installation, reverse the removal proce- dure. 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. 125 Nm (12.5 m kgf, 90 ft lbf)T.R.New E E E E E LS LS E 2425 (6)
haha CLUTCH 5-55 Removing the clutch master cylinder Order Job/Parts to remove Q ’ty Remarks Clutch fluid Drain. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM ” on page 3-12. 1 Hand shield 1 2 Grip end 1 3 Rear view mirror 1 4 Upper hand shield bracket 1 5 Clutch master cylinder reservoir cap 1 6 Clutch master cylinder reservoir diaphragm holder 1 7 Clutch master cylinder reservoir diaphragm 1 8 Lower hand shield bracket 1 9 Clutch lever 1 10 Bushing 1 3 10 5 6 7 9 8 2 1 4 SNewNew LT 1.0 Nm (0.10 m kgf, 0.72 ft Ibf)T.R. 3.8 Nm (0.38 m kgf, 2.8 ft Ibf)T.R. 4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R. 6 Nm (0.6 m kgf, 4.3 ft Ibf)T.R. 14 Nm (1.4 m kgf, 10 ft Ibf)T.R. 17 Nm (1.7 m kgf, 12 ft Ibf)T.R. 27 Nm (2.7 m kgf, 20 ft Ibf)T.R. 30 Nm (3.0 m kgf, 22 ft Ibf)T.R. 1.2 Nm (0.12 m kgf, 0.87 ft Ibf)T.R. 1.5 Nm (0.15 m kgf, 1.1 ft Ibf)T.R.