2012 Na Yamaha Super Tenere Manual

							
haha CRANKSHAFT AND BALANCER
5-96
For example, if the lower crankcase J 1 and 
crankshaft web J 1 numbers are 4 and 1 re-
spectively, then the bearing size for J 1 is:
EAS23P1045
CHECKING THE CONNECTING RODS
1. Measure: Crankshaft-pin-to-big-end-bearing clearance
Out of specification   Replace the big end 
bearings.
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The following procedure applies to all of the 
connecting rods.
NOTICE
ECA13930
Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big 
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins, 
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con- necting rod and the big end lower bearing into 
the connecting rod cap.
TIP
Align the projections  “a” on the big end bearings 
with the notches  “b” in the connecting rod and 
connecting rod cap.
c. Put a piece of Plastigauge ® “1” on the crank-
shaft pin.
d. Assemble the connecting rod halves.
TIP
 Do not move the connecting rod or crankshaft 
until the clearance measurement has been 
completed.
 Lubricate the bolt threads and nut seats with 
molybdenum disulfide oil.
 Make sure the  “Y” mark  “c” on the connecting 
rod faces towards the left side of the crank-
shaft.
J
1 (crankcase) - J
1 (crankshaft web)
=
4 - 1 = 3 (brown)
  Bearing color code
1.Blue 2.Black 3.Brown 4.Green 
5.Yellow
  Oil clearance
0.029 –0.053 mm (0.0011– 0.0021 
in)
J1 J2 J3
J1 J2 J3
A
J1J2
J3B
1   
						

							
haha CRANKSHAFT AND BALANCER
5-97
 Make sure the characters  “d” on both the con-
necting rod and connecting rod cap are 
aligned.
 Make sure that the projection “e”  on the con-
necting rod cap faces the same direction as the 
“Y”  mark  “c” on the connecting rod.
e. Tighten the connecting rod nuts. Refer to  “INSTALLING THE CONNECTING 
RODS ” on page 5-99.
f. Remove the connecting rod and big end  bearings.
Refer to  “REMOVING THE CONNECTING 
RODS ” on page 5-94.
g. Measure the compressed Plastigauge® 
width  “f” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing 
clearance is out of specification, select re-
placement big end bearings.
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2. Select: Big end bearings (P
1–P
2)
TIP

The numbers “A”  stamped into the crankshaft 
web and the numbers “B”  on the connecting 
rods are used to determine the replacement 
big end bearing sizes.
 P 1–P
2 refer to the bearings shown in the crank-
shaft illustration. For example, if the connecting rod P
1 and the 
crankshaft web P 1 numbers are 5 and 2 re-
spectively, then the bearing size for P 1 is:
EAS26120
CHECKING THE FRONT BALANCER
1. Check: Front balancer shaft
Cracks/damage/wear   Replace the front 
balancer shaft and journal bearings.
Dirt   Clean.
 Bearings
Damage/wear   Replace.
d
c
e
fP1 (connecting rod) - P
1 (crankshaft web)
=
5 - 2 = 3 (brown)
  Bearing color code
1.Blue 2.Black 3.Brown 4.Green
P1 P2
P2P1A
H5
B  
						

							
haha CRANKSHAFT AND BALANCER
5-98
2. Measure: Balancer shaft-journal-to-balancer shaft-jour-
nal-bearing clearance
Out of specification   Replace the balancer 
shaft journal bearings.
NOTICE
ECA23P1048
Do not interchange the balancer shaft jour-
nal bearings. To obtain the correct balancer 
shaft-journal-to-balancer shaft-journal-bear-
ing clearance and prevent engine damage, 
the balancer shaft journal bearings must be 
installed in their original positions.
▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼
a. Clean the front balancer shaft journal bear-
ings, front balancer shaft journals, and bear-
ing portions of the crankcase.
b. Install the front balancer shaft journal lower 
bearings  “1” and the front balancer shaft into 
the lower crankcase.
TIP
Align the projections “a”  on the front balancer 
shaft journal lower bearings with the notches  “b” 
in the lower crankcase.
c. Put a piece of Plastigauge® “2” on each front 
balancer shaft journal.
TIP
Do not put the Plastigauge ® over the oil hole in 
the front balancer shaft journal. d. Install the front balancer shaft journal upper 
bearings  “3” into the upper crankcase and as-
semble the crankcase halves.
TIP
 Align the projections  “c” of the front balancer 
shaft journal upper bearings with the notches 
“d”  in the upper crankcase.
 Do not move the front balancer shaft until the 
clearance measurement has been completed.
e. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase.
Refer to “ CRANKCASE”  on page 5-81.
f. Remove the upper crankcase and the bal- ancer shaft journal upper bearings.
g. Measure the compressed Plastigauge® 
width  “e” on each front balancer shaft journal.
If the balancer shaft-journal-to-balancer 
shaft-journal-bearing clearance is out of 
specification, select replacement front bal-
ancer shaft journal bearings.
▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
  Balancer shaft-journal-to-balanc-
er shaft-journal-bearing clear-
ance
0.016 –0.040 mm (0.0006– 0.0016 
in)
a
1
b
2
c
3 d
e  
						

							
haha CRANKSHAFT AND BALANCER
5-99
3. Select: Front balancer shaft journal bearings (J
1–J
3)
TIP

The numbers  “A” stamped into the lower crank-
case and the numbers “B”  stamped into the 
front balancer shaft web are used to determine 
the replacement front balancer shaft journal 
bearing sizes.
 J 1–J
3 refer to the bearings shown in the lower 
crankcase and front balancer shaft web illus-
tration.
 If J
1–J
3 are the same, use the same size for all 
of the bearings.
For example, if the lower crankcase J 1 and 
front balancer shaft web J 1 numbers are 6 
and 5 respectively, then the bearing size for 
J 1 is: EAS26150
INSTALLING THE CONNECTING RODS
1. Lubricate:
Bolt threads
 Nut seats
(with the recommended lubricant)
2. Lubricate: Crankshaft pins
 Big end bearings
 Connecting rod inner surface
(with the recommended lubricant)
3. Install: Big end bearings
 Connecting rods
 Connecting rod caps
(onto the crankshaft pins)
TIP
Align the projections  “a” on the big end bear-
ings with the notches  “b” in the connecting rods 
and connecting rod caps.
 Be sure to reinstall each big end bearing in its 
original place.
 Make sure the  “Y” marks  “c” on the connecting 
rods face towards the left side of the crank-
shaft.
 Make sure the characters  “d” on both the con-
necting rod and connecting rod cap are 
aligned.
 Make sure that the projection  “e” on the con-
necting rod cap faces the same direction as the 
“Y”  mark  “c” on the connecting rod.
J 1 (crankcase) - J
1 (balancer shaft web)
=
8 - 5 = 3 (brown)
J1 J2J3
J1 J2J3A
J1 J2 J3
B
  Bearing color code
1.Blue 2.Black 3.Brown 4.Green
  Recommended lubricant
Molybdenum disulfide oil
  Recommended lubricant
Engine oil   
						

							
haha CRANKSHAFT AND BALANCER
5-100
4. Tighten: Connecting rod nuts
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WARNING
EWA13390
Replace the connecting rod bolts and nuts 
with new ones.
Clean the connecting rod bolts and nuts.
TIP
Tighten the connecting rod bolts using the fol-
lowing procedure.
a. Tighten the connecting rod nuts with a torque 
wrench.
b. Put a mark  “1” on the corner of the connecting 
rod nut “2”  and the connecting rod cap  “3”.
c. Tighten the connecting rod nuts further to  reach the specified angle 145 –155°.
WARNING
EWA13400
If the connecting rod nut is tightened more 
than the specified angle, do not loosen the 
nut and then retighten it. Instead, replace the 
connecting rod bolt and nut with a new one 
and perform the procedure again.
NOTICE
ECA23P1049
 Do not use a torque wrench to tighten the 
connecting rod nut to the specified angle.
 Tighten the nut until it is at the specified an-
gle.
TIP
On a hexagonal nut, note that the angle from 
one corner to another is 60 °.
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EAS26200
INSTALLING THE CRANKSHAFT
1. Install: Crankshaft journal upper bearings
(into the upper crankcase)
 Crankshaft journal lower bearings
(into the lower crankcase)
TIP
Align the projections  “a” on the crankshaft jour-
nal bearings  “1” with the notches  “b” in the 
crankcase.
 Be sure to install each crankshaft journal bear-
ing in its original place.
T R..  Connecting rod nut (1st)
20 Nm (2.0 m· kgf, 14 ft·lbf)
T R..  Connecting rod nut (final)
Specified angle 145– 155°
d
c
e
c. Oil groove
145–15530
30
c
1
a
b    
						

							
haha CRANKSHAFT AND BALANCER
5-101
EAS26220
INSTALLING THE FRONT BALANCER 
SHAFT
1. Install: Front balancer shaft journal upper bearings
(into the upper crankcase)
 Front balancer shaft journal lower bearings
(into the lower crankcase)
TIP
Align the projections “a”  on the front balancer 
shaft journal bearings “1”  with the notches “b” 
in the crankcase.
 Be sure to install each front balancer shaft jour-
nal bearing in its original place.
2. Install: Front balancer shaft  “1”
TIP
Align the punch mark  “a” in the crankshaft with 
the punch mark  “b” in the front balancer shaft.
a
1
b
1 b
a  
						

							
haha TRANSMISSION
5-102
EAS26241
TRANSMISSION Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q ’ty Remarks
Crankcase Separate.
Refer to 
“CRANKCASE ” on page 5-81.
1 Drive axle/middle drive pinion gear assembly 1
2 Shift drum lower retainer 1
3 Shift fork lower guide bar 1 124.5 mm (4.90 in)
4Spring 2
5 Shift fork-L 1
6 Shift fork-R 1
7 Shift drum upper retainer 1
8 Shift fork upper guide bar 1 127.8 mm (5.03 in)
9 Shift fork-C 1
10 Shift drum assembly 1
LTLT
LTLT
E
E
E
FWD
E
E
EE
LTLT
LTLT
2
14
4
3 7
10
8
9
6
5
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
12 Nm (1.2 m 
kgf, 8.7 ft 
Ibf)T.R.  
						

							
haha TRANSMISSION
5-103
Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q ’ty Remarks
11 Main axle assembly 1
12 Bearing 1
For installation, reverse the removal proce-
dure.
LTLT
LTLT
E
E
E
FWD
E
E
EE
LTLT
LTLT
12
11
10 Nm (1.0 m 
kgf, 7.2 ft 
Ibf)T.R.
12 Nm (1.2 m 
kgf, 8.7 ft 
Ibf)T.R.  
						

							
haha TRANSMISSION
5-104
Disassembling the main axle Order Job/Parts to remove Q ’ty Remarks
1 Circlip 1
2 2nd pinion gear 1
3 Toothed lock washer 1
4 Toothed lock washer retainer 1
5 6th pinion gear 1
6 Toothed spacer 1
7 Toothed washer 1
8 Circlip 1
9 3rd/4th pinion gear 1
10 Circlip 1
11 Toothed washer 1
12 5th pinion gear 1
1
2
3
4
5
6
7
8 9
10
11
12New
New
New
M
M
M
M
M
M
M
M
E  
						

							
haha TRANSMISSION
5-105
Disassembling the main axle Order Job/Parts to remove Q ’ty Remarks
13 Collar 1
14 Bearing housing 1
15 Spacer 1
16 Bearing 1
17 Main axle/1st pinion gear 1
For assembly, reverse the disassembly pro-
cedure.
13
17
16
15
14
M
M
M
M
M
M
M
M
E