2012 Na Yamaha Super Tenere Manual

							
haha CLUTCH
5-56
Removing the clutch master cylinder Order Job/Parts to remove Q ’ty Remarks
11 Clutch switch coupler 1 Disconnect.
12 Clutch switch 1
13 Clutch hose union bolt 1
14 Clutch hose gasket 2
15 Clutch hose 1
16 Clutch master cylinder holder 1
17 Clutch master cylinder 1
For installation, reverse the removal proce-
dure.
16
11
17
14
15
12
13
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.  
						

							
haha CLUTCH
5-57
Disassembling the clutch master cylinder Order Job/Parts to remove Q ’ty Remarks
1 Clutch master cylinder push rod 1
2 Clutch master cylinder kit 1
3 Clutch master cylinder body 1 For assembly, reverse the disassembly pro-
cedure.
3
21
New
BF
S  
						

							
haha CLUTCH
5-58
Removing the clutch release cylinder Order Job/Parts to remove Q ’ty Remarks
Clutch fluid Drain.
Refer to 
“BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM ” on page 3-12.
1 Clutch hose union bolt 1
2 Clutch hose gasket 2
3 Clutch hose 1 Disconnect.
4 Clutch release cylinder 1
5 Dowel pin 2
6 Clutch release cylinder plate 1
7 Oil seal 1
For installation, reverse the removal proce-
dure.
New
New
LTLT
LT
LT
LS
6 5
5
4 1
3
7
2
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
30 Nm (3.0 m 
kgf, 22 ft 
Ibf)T.R.  
						

							
haha CLUTCH
5-59
EAS25070
REMOVING THE CLUTCH
1. Remove: Clutch cover  “1”
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the 
bolts are fully loosened, remove them. 
2. Remove:
Clutch spring plate retainer  “1”
 Clutch spring plate  “2”
TIP
Loosen the clutch spring plate retainer bolts in 
stages and in a crisscross pattern.
3. Remove:
Friction plates
 Clutch plates
TIP
Before removing friction plate 1, put an identifi-
cation mark “a”  on the plate. 4. Remove:
Long clutch push rod “1”
TIP
Push the long clutch push rod into the clutch re-
lease cylinder side of the engine, and remove it 
from the clutch side of the engine.
5. Straighten the clutch boss nut rib “a”.
6. Loosen:
Clutch boss nut  “1”
TIP
While holding the clutch boss  “2” with the univer-
sal clutch holder  “3”, loosen the clutch boss nut.
7. Remove: Clutch boss nut  “1”
 Conical spring washer  “2”
 Clutch boss assembly  “3”
1
2
1
a
  Universal clutch holder
90890-04086
YM-91042
1
a
2
1
3  
						

							
haha CLUTCH
5-60
TIP
There is a built-in damper between the clutch 
boss and the clutch plate. It is not necessary to 
remove the wire circlip  “4” and disassemble the 
built-in damper unless there is serious clutch 
chattering.
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
Friction plate
Damage/wear   Replace the friction plates 
as a set.
2. Measure: Friction plate thickness
Out of specification   Replace the friction 
plates as a set.
TIP
Measure the friction plate at four places. EAS25111
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch plates.
1. Check:
Clutch plate
Damage   Replace the clutch plates as a 
set.
2. Measure: Clutch plate warpage
(with a surface plate and thickness gauge  “1”)
Out of specification   Replace the clutch 
plates as a set.
EAS25130
CHECKING THE CLUTCH SPRING PLATE
1. Check: Clutch spring plate retainer
Damage   Replace.
  Friction plate 1, 2 thickness
2.92– 3.08 mm (0.115– 0.121 in)
Wear limit 2.82 mm (0.1110 in)
Friction plate 3 thickness 2.90– 3.10 mm (0.114– 0.122 in)
Wear limit 2.80 mm (0.1110 in)
3
1
2
4
A. Friction plate 1, 2
B. Friction plate 3
 Thickness gauge
90890-03180
Feeler gauge set YU-26900-9
  Clutch plate thickness
1.90– 2.10 mm (0.075 –0.083 in)
Warpage limit 0.10 mm (0.0039 in)
AB    
						

							
haha CLUTCH
5-61
2. Check: Clutch spring plate seat
Damage   Replace.
3. Measure: Clutch spring free height
Out of specification   Replace the clutch 
spring plate.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check: Clutch housing dogs
Damage/pitting/wear   Deburr the clutch 
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check: Bearing
Damage/wear   Replace the bearing and 
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check: Clutch boss splines
Damage/pitting/wear   Replace the clutch 
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
Pressure plate
Cracks/damage   Replace.
 Bearing
Damage/wear   Replace.
EAS25191
CHECKING THE CLUTCH PUSH RODS
1. Check: Short clutch push rod
 Long clutch push rod
 Ball
Cracks/damage/wear   Replace the defec-
tive part(s).
2. Measure:
Long clutch push rod bending limit
(with a centering device and dial gauge  “1”)
Out of specification   Replace.
EAS25210
CHECKING THE PRIMARY DRIVEN GEAR
1. Check: Primary driven gear  “1”
Damage/wear   Replace the primary drive 
and primary driven gears as a set.
  Clutch spring height
6.78 mm (0.27 in)
Minimum height 6.44 mm (0.25 in)
  Long clutch push rod bending 
limit
0.2 mm (0.0079 in)
1  
						

							
haha CLUTCH
5-62
Excessive noise during operation   Replace 
the clutch housing and crankshaft as a set.
EAS25250
INSTALLING THE CLUTCH
1. Install: Thrust plate  “1”
 Spacer
 Clutch housing
TIP
Install the thrust plate  “1” with the paint mark  “a” 
facing out.
2. Install:
Clutch boss assembly  “1”
TIP
If the wire circlip  “2” has been removed, care-
fully install a new one.
 Install the clutch damper spring  “3” with the 
“OUTSIDE ” mark facing out.
3. Install: Clutch boss assembly  “1”
 Conical spring washer  “2” 
Clutch boss nut  “3” 
TIP
Lubricate the conical spring washer and clutch 
boss nut threads with engine oil.
 Install the conical spring washer  “2” with the 
“ OUT”  mark  “a” facing out.
 While holding the clutch boss with the univer-
sal clutch holder  “4”, tighten the clutch boss 
nut.
 Stake the clutch boss nut  “3” at cutouts  “b” in 
the main axle.
4. Lubricate: Friction plates
 Clutch plates
(with the recommended lubricant)
5. Install: Friction plates
 Clutch plates
TIP
First, install a friction plate and then alternate 
between a clutch plate and a friction plate.
 Friction plate 1  “1”, which has an identification 
mark made before removal, must be installed 
last.
 Offset friction plate 1  “1” from the other friction 
plates  “2”, making sure to align a projection on 
friction plate 1 with the punch mark  “a” on the 
clutch housing.
1
a
1
1
3
2
New
T R..  Clutch boss nut
125 Nm (12.5 m ·kgf, 90 ft· lbf)
  Universal clutch holder
90890-04086
YM-91042
  Recommended lubricant
Engine oil
New
1
2 a
b
3
4
New  
						

							
haha CLUTCH
5-63
6. Install: Clutch spring plate  “1”
 Clutch spring plate retainer  “2”
TIP
Tighten the clutch spring plate retainer bolts in 
stages and in a crisscross pattern.
7. Install:
Clutch cover damper  “1”
 Clutch cover damper plate  “2”
TIP
Align the arrow mark “a” on the clutch cover 
damper with the arrow mark  “b” on the clutch 
cover damper plate. 8. Install:
Clutch cover  “1”
TIP
Tighten the clutch cover bolts in the proper tight-
ening sequence as shown.
EAS25280
DISASSEMBLING THE CLUTCH MASTER 
CYLINDER
NOTICE
ECA13840
Clutch components rarely require disas-
sembly.
 Therefore, always follow these preventive 
measures:
 Never disassemble clutch components un-
less absolutely necessary.
 If any connection on the hydraulic clutch 
system is disconnected, the entire clutch 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas-
sembly.
 Never use solvents on internal clutch com-
ponents.
 Use only clean or new clutch fluid for clean-
ing clutch components.
T R..  Clutch spring plate retainer bolt
8 Nm (0.8 m ·kgf, 5.8 ft· lbf)
T R.. Clutch cover damper plate bolt
10 Nm (1.0 m· kgf, 7.2 ft·lbf)
a
1
2
1
2
a b
1 2
T R.. Clutch cover bolt
12 Nm (1.2 m ·kgf, 8.7 ft· lbf)
LOCTITE ®
3,19
1,9,251
2,16,32
10,26
11,27
12,28 13,29
14,30
15,31
18,34
17,33
4,20
5,21
6,227,23
8,24  
						

							
haha CLUTCH
5-64
 Clutch fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt fluid immediately.
 Avoid clutch fluid coming into contact with 
the eyes as it can cause serious injury.
 First aid for clutch fluid entering the eyes:
 Flush with water for 15 minutes and get im-
mediate medical attention.
TIP
Before disassembling the clutch master cylinder, 
drain the clutch fluid from the entire clutch sys-
tem.
1. Remove:
Clutch hose union bolt “1”
 Clutch hose gaskets  “2”
 Clutch hose  “3”
TIP
To collect any remaining clutch fluid, place a 
container under the master cylinder and the end 
of the clutch hose.
EAS25290
CHECKING THE CLUTCH MASTER 
CYLINDER
1. Check:
Clutch master cylinder body
Cracks/damage   Replace the clutch mas-
ter cylinder.
 Clutch fluid delivery passage
(clutch master cylinder body)
Obstruction   Blow out with compressed air. 2. Check:
Clutch master cylinder kit
Rust/scratches/wear   Replace.
3. Check: Clutch master cylinder reservoir
Cracks/damage   Replace.
 Clutch master cylinder reservoir diaphragm
Damage/wear   Replace.
4. Check:
Clutch hose
Cracks/damage/wear   Replace.
EAS25300
ASSEMBLING THE CLUTCH MASTER 
CYLINDER
WARNING
EWA13340
 Before installation, all internal clutch com-
ponents must be cleaned and lubricated 
with clean or new clutch fluid.
 Never use solvents on internal clutch com-
ponents as they will cause the piston seals 
to swell and distort.
 Whenever a clutch master cylinder is disas-
sembled, replace the piston seals.
EAS25310
INSTALLING THE CLUTCH MASTER 
CYLINDER
1. Install: Clutch master cylinder  “1”
 Clutch master cylinder holder  “2”
TIP
The clutch master cylinder holder should be in-
stalled with the punch mark “a”  forward.
 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.
Recommended clutch component replace-
ment schedule
Piston seals Every two years
Clutch hose Every four years
Clutch fluid Every two years and 
whenever the clutch 
is disassembled
2
1
3
  Specified brake and clutch fluid
DOT 4
T R..  Clutch master cylinder holder 
bolt
14 Nm (1.4 m ·kgf, 10 ft· lbf)  
						

							
haha CLUTCH
5-65
2. Install: Clutch hose gaskets  “1” 
 Clutch hose  “2”
 Clutch hose union bolt “3”
WARNING
EWA23P1014
Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to  “CABLE 
ROUTING ” on page 2-43.
NOTICE
ECA23P1041
When installing the clutch hose onto the 
clutch master cylinder, make sure the clutch 
pipe  “a” touches the projection  “b” as 
shown.
TIP
Turn the handlebars to the left and to the right to 
make sure the clutch hose does not touch other 
parts (e.g., wire harness, cables, leads). Correct 
if necessary. 
3. Fill:
Clutch master cylinder reservoir
(with the specified amount of the specified 
brake and clutch fluid)
WARNING
EWA13370
Use only the designated clutch fluid. Other 
clutch fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
clutch performance.
 Refill with the same type of clutch fluid that 
is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.
 When refilling, be careful that water does 
not enter the clutch fluid reservoir. Water 
will significantly lower the boiling point of 
the clutch fluid and could cause vapor lock.
NOTICE
ECA13420
Clutch fluid may damage painted surfaces or 
plastic parts. Therefore, always clean up any 
spilt clutch fluid immediately.
TIP
In order to ensure a correct reading of the clutch 
fluid level, make sure the top of the reservoir is 
horizontal.
4. Bleed:
Clutch system
Refer to “ BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM ” on page 3-12.
5. Check: Clutch fluid level
Below the minimum level mark  “a”  Add the 
specified brake and clutch fluid to the proper 
level.
Refer to “ CHECKING THE CLUTCH FLUID 
LEVEL”  on page 3-12.
EAS23P1097
REMOVING THE CLUTCH RELEASE 
CYLINDER
1. Remove: Clutch hose union bolt  “1”
 Clutch hose gaskets  “2”
 Clutch hose  “3”
T R.. Clutch hose union bolt
30 Nm (3.0 m· kgf, 22 ft·lbf)
  Specified brake and clutch fluid
DOT 4
a
2
1
b
New
1New
3
2
a
b
LOWER UPPER
a