2012 Na Yamaha Super Tenere Manual
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haha RADIATOR 6-2 Removing the radiator Order Job/Parts to remove Q ’ty Remarks 8 Radiator cap 1 9 Radiator cover 1 10 Radiator fan motor coupler 1 Disconnect. 11 Radiator fan 1 12 Radiator 1 13 Left side panel 1 14 Radiator inlet hose 1 For installation, reverse the removal proce- dure. 14 911 8 13 10 12 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.4.5 Nm (0.45 m kgf, 3.3 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R. 2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R. 2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R.2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R. 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)T.R. 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)T.R.
haha RADIATOR 6-3 EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins Obstruction Clean. Apply compressed air to the inner side of the radiator. Damage Repair or replace. TIP Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: Radiator hoses Radiator pipe Cracks/damage Replace. 3. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Install the radiator cap tester “1” and radiator cap tester adapter “2” to the radiator cap “3”.b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 4. Check: Radiator fan Damage Replace. Malfunction Check and repair. Refer to “ COOLING SYSTEM ” on page 8-27. EAS26400 INSTALLING THE RADIATOR 1. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to “ CHANGING THE COOLANT ” on page 3-27. 2. Check: Cooling system Leaks Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “ CHECKING THE RADIATOR ” on page 6-3. Radiator cap opening pressure 93.3– 122.7 kPa (0.93 –1.23 kgf/cm ², 13.5– 17.8 psi) Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984
haha THERMOSTAT 6-4 EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q ’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT ” on page 3-27. Throttle bodies Refer to “THROTTLE BODIES ” on page 7-6. 1 Coolant temperature sensor coupler 1 Disconnect. 2 Coolant temperature sensor 1 3 Copper washer 1 4 Radiator inlet hose 1 5 Thermostat cover 1 6 Thermostat 1 For installation, reverse the removal proce- dure. 18 Nm (1.8 m kgf, 13 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. 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)T.R. New1 2 3 4 5 6
haha THERMOSTAT 6-5 EAS26450 CHECKING THE THERMOSTAT 1. Check: Thermostat Does not open at 69– 73 °C (156.2 –163.4 °F) Replace. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. b. Slowly heat the water “3”. c. Place a thermometer “4” in the water. d. While stirring the water, observe the thermo- stat and thermometer ’s indicated tempera- ture. TIP If the accuracy of the thermostat is in doubt, re- place it. A faulty thermostat could cause serious overheating or overcooling. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲2. Check: Thermostat cover Cracks/damage Replace. EAS26480 INSTALLING THE THERMOSTAT 1. Install: Thermostat TIP Install the thermostat with its breather hole “a” facing forward. 2. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to “ CHANGING THE COOLANT ” on page 3-27. 3. Check: Cooling system Leaks Repair or replace any faulty part. 4. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “ CHECKING THE RADIATOR ” on page 6-3. A. Fully closed B. Fully open a
haha WATER PUMP 6-6 EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q ’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT ” on page 3-27. 1 Water pump inlet hose 1 2 Lead holder 1 3 Water pump assembly 1 4 Water pump outlet pipe 1 5 Water pump breather hose 1 For installation, reverse the removal proce- dure. 5 1 2 3 4 New LS New LS LT LT LT 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R. 2.0 Nm (0.20 m kgf, 1.4 ft Ibf)T.R. 2.5 Nm (0.25 m kgf, 1.8 ft Ibf)T.R.
haha WATER PUMP 6-7 Disassembling the water pump Order Job/Parts to remove Q ’ty Remarks 1 Water pump housing cover 1 2Gasket 1 3 Circlip 1 4 Impeller shaft 1 5 Water pump seal 1 6 Bearing 1 7 Oil seal 1 8 Water pump housing 1 9 Rubber damper holder 1 10 Rubber damper 1 11 Water pump seal assembly 1 For assembly, reverse the disassembly pro- cedure. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 1 4 10 11 95 7 2 8 6 3 New New New New New New New E
haha WATER PUMP 6-8 EAS26510 DISASSEMBLING THE WATER PUMP 1. Remove: Water pump seal “1” TIP Remove the water pump seal from the inside of the water pump housing “2”. 2. Remove: Bearing “1” Oil seal “2” TIP Remove the bearing and oil seal from the out- side of the water pump housing “3”. 3. Remove: Rubber damper holder “1” Rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) TIP Do not scratch the impeller shaft. EAS26541 CHECKING THE WATER PUMP 1. Check: Water pump housing cover Water pump housing Impeller shaft Water pump seal Oil seal Cracks/damage/wear Replace. 2. Check: Bearing Rough movement Replace. 3. Check: Water pump outlet pipe Water pump inlet hose Cracks/damage/wear Replace. EAS26560 ASSEMBLING THE WATER PUMP 1. Install: Rubber damper holder “1” Rubber damper “2” TIP Before installing the rubber damper, apply tap water or coolant onto its outer surface. 2. Measure: Impeller shaft tilt Out of specification Repeat steps (1) and (2). NOTICE ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller. 1 2 1 2 3 1 2 Impeller shaft tilt limit 0.15 mm (0.0059 in) New New 1 2New New
haha WATER PUMP 6-9 3. Install: Oil seal “1” (into the water pump housing “2”) TIP Install the oil seal with a socket “3” that matches its outside diameter. 4. Install: Water pump seal “1” (into the water pump housing “2”) NOTICE ECA14080 Never lubricate the water pump seal surface with oil or grease. TIP Apply coolant to the lip of the water pump seal. Install the water pump seal with the special tools. 5. Install: Impeller shaft “1” Circlip “2” TIP Be sure the circlip sharp-edged corner “a” is positioned opposite side to the bearing. After installation, check that the impeller shaft rotates smoothly. 1. Straightedge 2. Impeller Installed depth of oil seal “a” 0.5– 1.0 mm (0.02– 0.04 in) 2 1 New 3 a 2 1 New New Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driv- er 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 3. Mechanical seal installer 4. Middle driven shaft bearing driver A. Push down 1 4 3 2 ANew a 2 1 1
haha WATER PUMP 6-10 EAS26590 INSTALLING THE WATER PUMP 1. Install: Water pump assembly TIP Align the projection “a” on the impeller shaft “1” with the slot “b” in the front balancer shaft “2”. 2. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT ” on page 3-27. 3. Check: Cooling system Leaks Repair or replace the faulty part. 4. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “CHECKING THE RADIATOR ” on page 6-3. 1 a 2 b