2012 Na Yamaha Super Tenere Manual
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haha TRANSMISSION 5-106 Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks Middle drive pinion gear assembly Refer to “MIDDLE GEAR ” on page 5-112. 1 Bearing 1 2Washer 1 3 1st wheel gear 1 4Collar 1 5 5th wheel gear 1 6 Circlip 1 7 Toothed washer 1 8 3rd wheel gear 1 9 Toothed spacer 1 10 Toothed lock washer 1 11 Toothed lock washer retainer 1 New M E 1 62 7 8 9 10 11 3 4 5 M M M M M M
haha TRANSMISSION 5-107 Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks 12 4th wheel gear 1 13 Collar 1 14 Toothed washer 1 15 Circlip 1 16 6th wheel gear 1 17 Circlip 1 18 Toothed washer 1 19 2nd wheel gear 1 20 Collar 1 21 Drive axle 1 For assembly, reverse the disassembly pro- cedure. New New M E 12 13 19 20 21 1415 16 18 17 M M M M M M
haha TRANSMISSION 5-108 EAS26250 REMOVING THE TRANSMISSION 1. Remove: Main axle assembly “1” TIP Remove the main axle assembly with the slide hammer bolts “2” and weight. EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: Shift fork cam follower “1” Shift fork pawl “2” Bends/damage/scoring/wear Replace the shift fork. 2. Check: Shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends Replace. WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar. 3. Check: Shift fork movement (along the shift fork guide bar) Rough movement Replace the shift forks and shift fork guide bar as a set. 4. Check: Springs Cracks/damage Replace. EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: Shift drum groove Damage/scratches/wear Replace the shift drum assembly. Shift drum segment “1” Damage/wear Replace the shift drum as- sembly. Shift drum bearing “2” Damage/pitting Replace the shift drum as- sembly. EAS26300 CHECKING THE TRANSMISSION 1. Measure: Main axle runout (with a centering device and dial gauge “1”) Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084 YU-01083-3 2 2 1 1 2
haha TRANSMISSION 5-109 Out of specification Replace the main axle. 2. Measure: Drive axle runout (with a centering device and dial gauge “1”) Out of specification Replace the drive axle. 3. Check: Transmission gears Blue discoloration/pitting/wear Replace the defective gear(s). Transmission gear dogs Cracks/damage/rounded edges Replace the defective gear(s). 4. Check: Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies. 5. Check: Transmission gear movement Rough movement Replace the defective part(s). EAS23P1046 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1. Install: Circlip “1” TIP Install the circlip so that a spline “a” is in the cen- ter of the gap between the circlip ends “b” as shown. 2. Install: Toothed lock washer retainer “1” Toothed lock washer “2” TIP With the toothed lock washer retainer in the groove “a” in the axle, align the projection on the retainer with an axle spline, and then install the toothed lock washer. Be sure to align the projection on the toothed lock washer that is between the alignment marks “b” with the alignment mark “c” on the re- tainer. Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) 1 1 New New a 1 b
haha TRANSMISSION 5-110 3. Install: Bearing “1” TIP Be sure to install the bearing so that the seal “2” is facing outward. EAS26350 INSTALLING THE TRANSMISSION 1. Install: Bearing “1” TIP Face the seal side of the bearing to the outside and install it close to the left side end of the up- per crankcase. 2. Install: Main axle assembly “1” Main axle bearing housing bolts TIP When installing the main axle assembly, use a pin “2” to align the bearing housing hole with the corresponding hole in the upper crankcase. 3. Install: Shift drum assembly Shift fork-C Shift fork upper guide bar Shift fork-R Shift fork-L Springs Shift fork lower guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C” , “L”. 4. Install: Shift drum upper retainer “1” Shift drum lower retainer “2” A. Main axle B. Drive axle 2 1 c b b 1 2 a A 2 b b 1c 1 2 a B 1 2 T R.. Main axle bearing housing bolt 12 Nm (1.2 m ·kgf, 8.7 ft· lbf) LOCTITE ® T R.. Shift drum retainer screw 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) LOCTITE ® 1 2 1
haha TRANSMISSION 5-111 TIP Install each shift drum retainer with its “OUT” mark “a” facing outward. Align the projection “b” on the shift fork upper guide bar with the slot “c” in the shift drum up- per retainer. 5. Check: Transmission Rough movement Repair. TIP Oil each gear, shaft, and bearing thoroughly. b c a 2 1
haha MIDDLE GEAR 5-112 EAS25711 MIDDLE GEAR Removing the middle driven pinion gear Order Job/Parts to remove Q ’ty Remarks Engine Refer to “ENGINE REMOVAL ” on page 5-3. 1 Middle gear side cover 1 2 Middle gear side cover gasket 1 3 Dowel pin 2 4 Middle gear side cover damper plate 1 5 Middle gear side cover damper 1 6 Circlip 4 7 Bearing 4 8 Universal joint 1 9 Middle driven pinion gear assembly 1 10 Middle driven pinion gear shim Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH ” on page 5-120 and “ALIGNING THE MIDDLE GEAR ” on page 5-122. 10 8 106 9 7 7 7 7 66 6 12 (6) 3 3 4 5 (4) 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.LTLT 33 Nm (3.3 m kgf, 24 ft Ibf)T.R. LT E LS LS LS LT LT LS LS LS LS LS New New E E FWD
haha MIDDLE GEAR 5-113 Removing the middle driven pinion gear Order Job/Parts to remove Q ’ty Remarks 11 Universal joint yoke nut 1 12 Washer 1 13 Universal joint yoke 1 14 Middle driven pinion gear 1 15 Expander 1 16 Bearing 1 17 Oil seal 1 18 Bearing 1 19 Bearing race 2 20 Middle driven pinion gear bearing housing 1 For installation, reverse the removal proce- dure. 14 12 13 11 16 19 181920 17 (6) (4) 15 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.LTLT 33 Nm (3.3 m kgf, 24 ft Ibf)T.R. LT E LS LS LS LT LT LS LS LS LS LS New New New New E E FWD
haha MIDDLE GEAR 5-114 Removing the middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks Crankcase Separate. Refer to “CRANKCASE ” on page 5-81. 1 Middle drive pinion gear bearing retainer 1 2 Middle drive pinion gear shim Refer to “ALIGNING THE MIDDLE GEAR ” on page 5-122. 3 Drive axle/middle drive pinion gear assembly 1 4 Spring retainer 2 5Washer 1 6 Middle drive pinion gear assembly 1 7 Torque damper cam 1 8Spring 1 9 Spring seat 1 10 Bearing 1 E LT FWD E M M 7 8 9 10 5 4 1 (4) 6 3 2 28 Nm (2.8 m kgf, 20 ft Ibf)T.R. 110 Nm (11 m kgf, 80 ft lbf)T.R.
haha MIDDLE GEAR 5-115 Removing the middle drive pinion gear Order Job/Parts to remove Q ’ty Remarks 11 Middle drive pinion gear nut 1 12 Middle drive pinion gear 1 13 Bearing 1 14 Middle drive pinion gear bearing housing 1 For installation, reverse the removal proce- dure. E LT FWD E M M New11 12 14 13 (4) 28 Nm (2.8 m kgf, 20 ft Ibf)T.R. 110 Nm (11 m kgf, 80 ft lbf)T.R.