2012 Na Yamaha Super Tenere Manual
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haha THROTTLE BODIES 7-10 Do not apply cleaning solvent directly to any plastic parts, sensors, or seals. Do not directly push the throttle valves to open them. Be careful not to remove the white paint mark that identifies the standard throttle body. Do not turn the bypass air screws “a” ; otherwise, the throttle body synchroni- zation will be affected. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Place the throttle bodies on a flat surface with the air filter case side facing up. b. Install the caps (895-14169-00) onto the hose fittings “a”. c. Push the lever in the direction shown in the il- lustration to hold the throttle valves in the open position. WARNING EWA23P1031 When cleaning the throttle bodies, be careful not to injure yourself on the throttle valves or other components of the throttle bodies. NOTICE ECA23P1067 Do not open the throttle valves by supplying electrical power to the throttle bodies. d. Apply a petroleum-based solvent to the throt- tle valves and the inside of the throttle bodies to remove any carbon deposits. TIP Do not allow any petroleum-based solvent to enter the opening for the injectors. Do not apply any petroleum-based solvent to the portions of the throttle valve shafts be- tween the throttle bodies. e. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the air filter case side of the throttle body to the engine side. NOTICE ECA23P1068 Do not use a tool, such as a wire brush, to remove the carbon deposits; otherwise, the inside of the throttle bodies may be dam- aged. Do not allow carbon deposits or other for- eign materials to enter any of the passages in each throttle body or in the space be- tween the throttle valve shaft and the throt- tle body. f. After removing the carbon deposits, clean the inside of the throttle bodies with a petroleum- based solvent, and then dry the throttle bod- ies using compressed air. g. Make sure that there are no carbon deposits or other foreign materials in any of the pas- sages “a” in each throttle body or in the space “b” between the throttle valve shaft and the throttle body. aa a
haha THROTTLE BODIES 7-11 ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 3. Adjust: Throttle bodies synchronizing Out of specification Replace the throttle bodies. Refer to “SYNCHRONIZING THE THROT- TLE BODIES ” on page 3-8. EAS21010 CHECKING THE THROTTLE BODY JOINTS 1. Remove: Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. Throttle bodies Refer to “THROTTLE BODIES ” on page 7-6. 2. Check: Throttle body joints “1” Cracks/damage Replace. 3. Install: Throttle bodies Refer to “THROTTLE BODIES ” on page 7-6. Air filter case Refer to “GENERAL CHASSIS ” on page 4-1. EAS23P1081 INSTALLING THE INJECTORS NOTICE ECA23P1069 Always use new O-rings. When checking the injectors, do not allow any foreign material to enter or adhere to the injectors, fuel rail, or O-rings. Be careful not to twist or pinch the O-rings when installing the injectors. If an injector is subject to strong shocks or excessive force, replace it. If installing the original fuel rail and screws, remove the white paint marks using a cleaning solvent. Otherwise, paint chips on the screw seats could prevent the screws from being tightened to the specified torque. 1. Install a new seals onto the end of each injec- tor. 2. Install the injectors “1” to the fuel rail “2”. 3. Install the injector assemblies to the throttle bodies. 4. Check the injector pressure after the injectors are installed to the throttle bodies. Refer to “ CHECKING THE INJECTOR PRESSURE ” on page 7-11. EAS23P1082 CHECKING THE INJECTOR PRESSURE TIP After installing the injectors, perform the follow- ing steps to check the injector pressure. Do not allow any foreign materials to enter the fuel lines. 1. Check: Injector pressure ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Connect the injector pressure adapter “1” to the fuel rail “2”, and then connect an air com- pressor “3” to the adapter. b. Connect the pressure gauge “4” to the injec- tor pressure adapter “1”. b a 1 T R.. Fuel rail screw 5 Nm (0.5 m ·kgf, 3.6 ft· lbf) Pressure gauge 90890-03153 YU-03153 Fuel injector pressure adapter 90890-03210 YU-03210 2 1
haha THROTTLE BODIES 7-12 c. Close the valve on the injector pressure adapter. d. Apply air pressure with the air compressor. e. Open the valve on the injector pressure adapter until the specified pressure is reached. NOTICE ECA23P1070 Never exceed the specified air pressure or damage could occur. f. Close the valve on the injector pressure adapter. g. Check that the specified air pressure is held for about one minute. Pressure drops Check the pressure gauge and adapter. Check the seals and O-rings and then rein- stall. Replace the fuel injectors. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS23P1083 CHECKING THE FUEL PRESSURE 1. Check: Fuel pressure ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Remove the fuel tank bolts “1” and holdup the fuel tank. NOTICE ECA23P1003 When lifting up the fuel tank, be careful not to pull the fuel tank overflow hose and fuel tank breather hose. b. Remove the fuel hose holder “2” and then disconnect the fuel hose “3” from the fuel tank. WARNING EWA23P1032 Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose. NOTICE ECA23P1071 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. c. Connect the pressure gauge “4” and adapter “5” to the fuel hose “3”. Specific air pressure 490 kPa (4.9 kgf/cm 2 , 69.7 psi) Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 1 3 2
haha THROTTLE BODIES 7-13 d. Start the engine. e. Measure the fuel pressure. Faulty Replace the fuel pump. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ EAS23P1084 ADJUSTING THE THROTTLE POSITION SENSOR WARNING EWA23P1033 Handle the throttle position sensor with special care. Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: Throttle position sensor Refer to “CHECKING THE THROTTLE PO- SITION SENSOR ” on page 8-143. 2. Adjust: Throttle position sensor angle ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Temporary tighten the throttle position sen- sor. b. Check that the throttle valves are fully closed. c. Connect the throttle position sensor to the wire harness. d. Turn the main switch to “OFF ”. e. Simultaneously press and hold the left set button “1” and right set button “2”, turn the main switch to “ON ”, and continue to press the buttons for 8 seconds more. TIP “ dIAG ” appears on the odometer LCD. f. Diagnostic code number “d:01” is selected. g. Adjust the position of the throttle position sen- sor angle so that 9 –20 can appear in the meter. h. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “3”. ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS23P1085 ADJUSTING THE ACCELERATOR POSITION SENSOR WARNING EWA23P1034 Handle the accelerator position sensor with special care. Never subject the accelerator position sen- sor to strong shocks. If the accelerator po- sition sensor is dropped, replace it. 1. Check: Accelerator position sensor Refer to “ CHECKING THE ACCELERATOR POSITION SENSOR ” on page 8-143. 2. Adjust: Accelerator position sensor angle ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Temporary tighten the accelerator position sensor. Output pressure 324.0 kPa (3.24 kgf/cm ², 47.0 psi) 5 3 4 T R.. Throttle position sensor screw 3.5 Nm (0.35 m ·kgf, 2.5 ft· lbf) 12 3 3
haha THROTTLE BODIES 7-14 b. Check that the throttle valves are fully closed. c. Connect the accelerator position sensor to the wire harness. d. Connect the throttle cables to the throttle bod- ies. e. Turn the main switch to “OFF ”. f. Simultaneously press and hold the left set button “1” and right set button “2”, turn the main switch to “ON ”, and continue to press the buttons for 8 seconds more. TIP “ dIAG ” appears on the odometer LCD. g. Diagnostic code number “d:14” is selected. h. Turn the throttle grip to the fully closed posi- tion. i. Adjust the position of the accelerator position sensor angle so that 12 –22 can appear in the meter. j. After adjusting the accelerator position sen- sor angle, tighten the accelerator position sensor screws “3”. k. Turn the throttle grip to the fully open position. l. Check the meter display value. If the meter display value is not 97 –113, adjust the accel- erator position sensor angle. m. Select the diagnostic code number “d:15”. n. Turn the throttle grip to the fully closed posi- tion. o. Check the meter display value. If the meter display value is not 9 –25, adjust the acceler- ator position sensor angle. p. Turn the throttle grip to the fully open position. q. Check the meter display value. If the meter display value is not 97 –113, adjust the accel- erator position sensor angle. r. Repeat steps (g) to (q) until the meter display values are within the specified ranges. s. If the meter display values are not within the specified ranges after repeating steps (g) to (q) several times, replace the accelerator po- sition sensor. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS23P1086 INSTALLING THE THROTTLE BODY JOINTS 1. Install: Throttle body joints “1” TIP Be sure to install the throttle body joint with the “L” mark onto the throttle body openings for cyl- inders #1 and the joint with the “R” mark onto the openings for cylinders #2. T R.. Accelerator position sensor screw 3.5 Nm (0.35 m ·kgf, 2.5 ft ·lbf) 12 3 T R.. Throttle body joint bolt 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) LR 1
haha 8 ELECTRICAL SYSTEM IGNITION SYSTEM ......................................................................................... 8-1 CIRCUIT DIAGRAM .................................................................................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION ....................... 8-3 TROUBLESHOOTING .............................................................................. 8-4 ELECTRIC STARTING SYSTEM .................................................................... 8-7 CIRCUIT DIAGRAM .................................................................................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-9 TROUBLESHOOTING ............................................................................ 8-10 CHARGING SYSTEM .................................................................................... 8-13 CIRCUIT DIAGRAM ................................................................................ 8-13 TROUBLESHOOTING ............................................................................ 8-15 LIGHTING SYSTEM ...................................................................................... 8-17 CIRCUIT DIAGRAM ................................................................................ 8-17 TROUBLESHOOTING ............................................................................ 8-19 SIGNALING SYSTEM ................................................................................... 8-21 CIRCUIT DIAGRAM ................................................................................ 8-21 TROUBLESHOOTING ............................................................................ 8-23 COOLING SYSTEM ....................................................................................... 8-27 CIRCUIT DIAGRAM ................................................................................ 8-27 TROUBLESHOOTING ............................................................................ 8-29 FUEL INJECTION SYSTEM .......................................................................... 8-31 CIRCUIT DIAGRAM ................................................................................ 8-31 ECU SELF-DIAGNOSTIC FUNCTION .................................................... 8-33 TROUBLESHOOTING METHOD ............................................................ 8-34 DIAGNOSTIC MODE .............................................................................. 8-34 TROUBLESHOOTING DETAILS ............................................................ 8-36 DIAGNOSTIC CODE TABLE .................................................................. 8-72 FUEL PUMP SYSTEM ................................................................................... 8-75 CIRCUIT DIAGRAM ................................................................................ 8-75 TROUBLESHOOTING ............................................................................ 8-77
haha ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 8-79 CIRCUIT DIAGRAM ................................................................................ 8-79 ABS COMPONENTS CHART ................................................................. 8-81 ABS COUPLER LOCATION CHART ...................................................... 8-83 MAINTENANCE OF THE ABS ECU ....................................................... 8-85 ABS TROUBLESHOOTING OUTLINE.................................................... 8-85 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 8-86 BASIC PROCESS FOR TROUBLESHOOTING ..................................... 8-87 [A] CHECKING THE ABS WARNING LIGHT .......................................... 8-88 [B-1] THE ABS WARNING LIGHT FAILS TO COME ON ....................... 8-88 [B-2] THE ABS WARNING LIGHT FLASHES ......................................... 8-88 [B-3] THE ABS WARNING LIGHT REMAINS ON ................................... 8-88 [B-4] THE ABS WARNING LIGHT COMES ON FOR 2 SECONDS, THEN GOES OFF ........................................................... 8-88 [B-5] MALFUNCTIONS ARE CURRENTLY DETECTED ........................ 8-89 [C-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON ............ 8-89 [C-2] ALL INDICATOR LIGHTS FAIL TO COME ON .............................. 8-89 [C-3] THE ABS WARNING LIGHT REMAINS ON................................... 8-90 [C-4] THE ABS WARNING LIGHT FLASHES ......................................... 8-91 [C-5] DIAGNOSIS USING THE FAULT CODES ..................................... 8-91 [D-1] DELETING THE FAULT CODES ................................................. 8-119 [D-2] DELETE FUNCTION TEST .......................................................... 8-119 [D-3] FINAL CHECK .............................................................................. 8-121 ELECTRICAL COMPONENTS .................................................................... 8-123 CHECKING THE SWITCHES ............................................................... 8-127 CHECKING THE BULBS AND BULB SOCKETS ................................. 8-130 CHECKING THE FUSES ...................................................................... 8-131 CHECKING AND CHARGING THE BATTERY ..................................... 8-132 CHECKING THE RELAYS .................................................................... 8-135 CHECKING THE TURN SIGNAL RELAY ............................................. 8-136 CHECKING THE RELAY UNIT (DIODE) .............................................. 8-136 CHECKING THE IGNITION COILS....................................................... 8-137 CHECKING THE IGNITION SPARK GAP............................................. 8-138 CHECKING THE CRANKSHAFT POSITION SENSOR........................ 8-138 CHECKING THE LEAN ANGLE SENSOR............................................ 8-139 CHECKING THE STARTER MOTOR OPERATION ............................. 8-139 CHECKING THE STATOR COIL .......................................................... 8-140 CHECKING THE RECTIFIER/REGULATOR ........................................ 8-140 CHECKING THE OIL LEVEL SWITCH ................................................. 8-140 CHECKING THE FUEL SENDER ......................................................... 8-141 CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT ....... 8-141 CHECKING THE OIL LEVEL WARNING LIGHT .................................. 8-142 CHECKING THE RADIATOR FAN MOTOR ......................................... 8-142 CHECKING THE COOLANT TEMPERATURE SENSOR..................... 8-142 CHECKING THE THROTTLE POSITION SENSOR ............................. 8-143 CHECKING THE ACCELERATOR POSITION SENSOR ..................... 8-143 CHECKING THE INTAKE AIR PRESSURE SENSOR ......................... 8-144 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................. 8-145 CHECKING THE FUEL INJECTORS .................................................... 8-145 CHECKING THE THROTTLE SERVO MOTOR ................................... 8-145
haha IGNITION SYSTEM 8-1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM B/LB/L1 W1(GRAY)W3 W2 (BLACK) BR2 WL B1 W1 WL B2 W2 Y2L/RB2LYB BL/BBrR/WB4 Br G/RB (GRAY)L/R2B4 (YELLOW) ChB (GRAY)Ch3B (GRAY) LDg B (BLACK)LDg B5 (BLACK) LChB (GRAY)L1ChB4 (GRAY) Dg B (BLACK)Dg3B3 (BLACK) B/GL/BLg/WBL/BB/GB5Lg/W BB/WBB/W L/WR2R/W2 RR1 B1 B2B4L/G R/B1Y3W/L1R/W1B Br3R/BR/WL/WG/YBBrW/GB/WB/W2W/G Br/LLR/W4G/Y Br1L/B1R/Y1Y/B Br/RL/YL/B Br/RB/R1B/R L/Y B/Y(BLACK) Br/ WBr4 L/Y B/Y(BLACK)L BR GB1 L/B YL/R3 W(BLACK) B/L6Gy (BLACK) BGy (BLACK) Br/GL/W2 R/B2 W/L2 R/L1 L/W3L/RR/W3L/GB/RSbB/YSb /W G/WB/L5(GREEN) B/G1R/W4 B/L7(BLACK)Gy/G2B/G3R/W5B/L8Gy/G BB L (BLACK) WBB L (BLACK) WB/LY/GLgL B2Br/BBr/YB (BLACK ) Dg2Y1Ch2 B/R B2B1Br/W B/Y2Br R/B3(BLACK) OR/B4(BLACK)Gy/RR/B5(BLACK)O/GR/B6(BLACK)Gy/G3Y/R(BLACK)Y/W Y1 Br2 (BROWN)Br Y (BROWN) B L(BLACK) GBR/ L3B1(DARK GREEN ) W GDg1Y/LCh1B/W1G/R R/W5Sb/WR/GY2 (GRAY) R/Y Br/WB Dg BrB/Y Y L/YCh ( BLACK ) L1P/WB/L1(DARK BLUE)B/L2W1(BLACK) B1L3B/LW2(BLACK)B2L1 W(BLACK) R/BR/L4(GRAY)G/BR/L5(GRAY) Br/W(BLACK)B/L4 LB1 B1 (BLACK) SbW/RLgSbB LgW/R RBr/L R1Br/L (GRAY) (GRAY) B/W6 B/W5 B/W4 B/W3 B/W1 B/W2 BB/LY/GL Lg LY/G B/LBLg Sb Sb Y/WB/R1B/W3B/Y1B/G2 O Gy/G3Gy/RO/G Y/R L/W4 W/GG/YG/BR/BB5 R/W2L/BY/G Lg L/R Y/B B4 Br/G L Gy/GR/L2B/W4 (BLACK) L/WL/W2 L/W3B/G1 L/W4 B/G2 L/W5 B/G3 R/L1 R/L2R/W1 R/W2 R/W4 R/L3R/W5 R/L4 Br R/L5 W/L1 B/L1 W/L2 B/L2 W/L B/L Y1B/L4Y2B/L5Y3B/L6Y4B/L7 B/L8 L1B/YL4B/Y2LB/Y1 P/WW2W1 Lg/WR/W1 B2 B1 Gy/G2 L4 L2 Br/WGy G/WY /L2 B/L2 B/L1(BLACK) B2L W2R2Br/W B/WB L/BDg Y4B/L1L/W5 Lg B1 Sb W1W/R G/RW /L ALEAN ANGLE SENSOR SUB-WIRE HARNESS WIRE HARNESS BNEUTRAL SWITCH SUB-WIRE HARNESS WIRE HARNESS MODE ON OFF W1 W2 W3 W1 W2 W3 B R5R5 R1 R2 R2 RR R1 R1 R R3 R4 R4 R R R/G Br/L Br/G R/W2 Br/W R R3 Br R L/WR/W2 R R B1 B B B/W R2 L/YBr/LB/R1Br/RB/RL/B R1 B DgBr1 Br/B Br/Y L/RB2B Br/B G/Y L L B1 BB/W5 L/R B4B1B B2 B B4 B G/R L/R2 LY2Y B3 B2 Lg/WL/BB/GB5 B Br Br B B5 B3 B2 B2 B4 B4 B5 B2 B1 BB3 L/B R/W L/R3 L/B B4 B4 B1B B B1 B3GL RY L/B1L/B1 Y/B Br1 Br1R/Y1 R/Y1 Br L/B2L/B B4 Y1Y L1Br2BrBr2Br4Br3 B Br L B1 L/R3 L/R2 L/R B/W2B/WW/G R/B1 R/B W/L1 L/WG/Y B Br3BrY3 R/W R/W R/W1 R/W3 R/W5 R/W4 R/W2 L/W3 R/W3 W/L2 R/L1 Sb B/RL /GL/R B/Y L/W2 R/B2 Br/G Sb/W Sb Sb Sb B/Y2 B/YL/Y L/B2R/YYY1 Y1Y2 Br/W Br/W Br B B1Ch Ch2 Dg Dg2 Dg2 Br4 Ch2Dg3Dg Ch1 Ch Ch Dg3 Dg Ch3 Ch L1 L Dg B4 B3 B B BB B5LW Dg1 Dg1 G/R Ch1 Y2G W Ch3 Y Y/L B/W1Sb/W L/GB4 B1 B2W/L2W/LY1 Y2Y3 Y4 L1 L4 L B/L1 B/L2 B/L B/L4 B/L5 B/L6B/L7 B/L8 B/YB /Y1 B/Y2 L/WL/W3 L/W2 L/W5 L/W4 R/W5BrR/W1 R/W4 B/G1 B/G2B/G3 R/W2 R/L1 R/L3 R/L2 R/L5 R/L4 R/L3G L3L1L2 B1 B R/B1 R/B2 R/B3 R/B4 R/B5 R/B6 Gy BGy L1B/L6 B/L1P/WR/W5Gy/GB/G3 B/L8 B/L7 R/W4 B/G1Gy/G2BL BW BL BWB/L Y/G Br/W B/L4 G/WB/G2 Gy/G Gy/G2 B/Y1P/WL/W4 W/G Gy/RO/G Gy/G3 O/G R/B6Gy/G3R/B5 Gy/R R/B4 R/B3 R/W1 L/R R/L2 G/W Br/W B/L5 Lg Y/GLg L4 Gy OO L B/L Y/GLg L B/L Y/GLg L B/L2B/L W1B1 L3 L1B/L B/L2 B/L1 B BB4B2 B1 B3 BB B Sb Lg B1 W/R Sb LgW/R L/W5 W/L G/RY4 B/L1 B/L3 B/L3 B/L2 B/L1 B/L1 B/L2 B B2 W2 B1 W1 B2 W2 B1 W1 L W L W B/WB/L1LR2Br/W L/BB/W6 B/W3 B/W4 B/W2 B/W1 B4B3B5 B4B5 B/W2 B/W1 LLg/WY/W Y/R Y/WY/R G/B R/B G/BR/B R/L5 R/L4 B1W1B/L1B/L2 L/B L2 B2W2 B2 W2Y/LG/Y Y/B B/W1 B/W6 B /W4 B/W2 B/W3 B/W5 R/W2 Br/G R/G Br/L R/W1 R/W R/W R/W4 R/W5 Br/L Br/L Br/L Br/R Br/R B/R1 B/R Br1 Dg W/L1 B A AAAA 1 23 4 56 789 101112 13 141516171819 20 21 22 23 24 25 26 27 2829 3031 3233 3435 36 373839404141414142434445 4647 4849 50 5152 53 545556 57 58 59 606162636465666768697071 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 9697 9899100 13 13 13 13 1313 13 13 13 13 13 13 13 13 13 13 13 13 13 13