2012 Na Yamaha Super Tenere Manual
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haha ELECTRICAL COMPONENTS 8-142 EAS29050 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. 1. Check: Oil level warning light “1” (Turn the main switch to “ON ”.) Warning light comes on for a few seconds, then goes off Warning light is OK. Warning light does not come on Replace the meter assembly. Warning light flashes ten times, then goes off for 3 seconds in a repeated cycle (malfunc- tion detected in oil level switch) Replace the oil level switch. EAS28250 CHECKING THE RADIATOR FAN MOTOR 1. Check: Radiator fan motor Faulty/rough movement Replace. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect the battery (DC 12 V) as shown. c. Measure the radiator fan motor movement. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS28261 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: Coolant temperature sensor Refer to “ THERMOSTAT ” on page 6-4. WARNING EWA14130 Handle the coolant temperature sensor with special care. Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- ature sensor is dropped, replace it. 2. Check: Coolant temperature sensor resistance Out of specification Replace. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Connect the pocket tester ( × 1k/ × 100) to the coolant temperature sensor terminals as shown. b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”. TIP Make sure the coolant temperature sensor ter- minals do not get wet. c. Place a thermometer “3” in the coolant. Positive tester probe Blue “1” Negative tester probe Black “2” 1 1 Coolant temperature sensor re- sistance 5.21– 6.37 k at 0 °C (32 °F) 290– 354 at 80 °C (176 ° F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C L B 1 2
haha ELECTRICAL COMPONENTS 8-143 d. Heat the coolant or let it cool down to the specified temperatures. e. Measure the coolant temperature sensor re- sistance. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 3. Install: Coolant temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1. Remove: Throttle position sensor (from the throttle body) WARNING EWA23P1027 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. 2. Check: Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Connect the pocket tester ( × 1k) to the throttle position sensor as shown. b. Check the throttle position sensor maximum resistance. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ 3. Install: Throttle position sensor TIP When installing the throttle position sensor, ad- just its angle properly. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR ” on page 7-13. EAS29100 CHECKING THE ACCELERATOR POSITION SENSOR 1. Remove: Accelerator position sensor (from the throttle body) WARNING EWA23P1028 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. 2. Check: Accelerator position sensor maximum resis- tance Out of specification Replace the accelera- tor position sensor. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Connect the pocket tester ( × 1k) to the ac- celerator position sensor terminals as shown. T R.. Coolant temperature sensor 18 Nm (1.8 m· kgf, 13 ft·lbf) Resistance 1.20– 2.80 k Pocket tester 90890-03112 Analog pocket tester YU-03112-C 3 1 2 Positive tester probe blue “1” Negative tester probe black/blue “2” Resistance 1.20– 2.80 k BLB/LW 1 2
haha ELECTRICAL COMPONENTS 8-144 b. Measure the accelerator position sensor maximum resistance. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 3. Install: Accelerator position sensor TIP When installing the accelerator position sensor, adjust its angle properly. Refer to “ADJUSTING THE ACCELERATOR POSITION SENSOR ” on page 7-13. EAS28411 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Remove: Intake air pressure sensor (from the throttle bodies) WARNING EWA23P1037 Handle the intake air pressure sensor with special care. Never subject the intake air pressure sen- sor to strong shocks. If the intake air pres- sure sensor is dropped, replace it. 2. Check: Intake air pressure sensor output voltage Out of specification Replace. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Connect the test harness S-pressure sensor (3P) between the intake air pressure sensor and wire harness. NOTICE ECA23P1082 Pay attention to the installing direction of the test harness S-pressure sensor (3P) coupler “a”. b. Connect the pocket tester (DC 20 V) to the test harness S-pressure sensor (3P). c. Turn the main switch to “ ON”. d. Measure the intake air pressure sensor out- put voltage. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe blue “1” Negative tester probe black/blue “2” Intake air pressure sensor output voltage 3.57– 3.71 V at 101.3 kPa BLB/LW 1 2 b. Wire harness Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness S- pressure sensor (3P) 90890-03207 YU-03207 Positive tester probe pink/white “1” Negative tester probe black/blue “2” b a LB/LP /W 12
haha ELECTRICAL COMPONENTS 8-145 EAS28421 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: Intake air temperature sensor (from the air filter case.) WARNING EWA14110 Handle the intake air temperature sensor with special care. Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: Intake air temperature sensor resistance Out of specification Replace. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Connect the pocket tester ( × 1k/ × 100) to the intake air temperature sensor terminals as shown. b. Immerse the intake air temperature sensor “1” in a container filled with water “2”. TIP Make sure the intake air temperature sensor ter- minals do not get wet. c. Place a thermometer “3” in the water. d. Heat the water or let it cool down to the spec- ified temperatures. e. Measure the intake air temperature sensor resistance. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲3. Install: Intake air temperature sensor EAS23P1072 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors. 1. Remove: Fuel injector Refer to “ THROTTLE BODIES ” on page 7-6. 2. Check: Fuel injector resistance Out of specification Replace the fuel injec- tor. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector. b. Connect the pocket tester ( × 10) to the fuel injector coupler as shown. c. Measure the fuel injector resistance. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ EAS23P1102 CHECKING THE THROTTLE SERVO MOTOR 1. Remove: Air filter case Refer to “ GENERAL CHASSIS ” on page 4-1. Intake air temperature sensor re- sistance 5.40– 6.60 k at 0 ° C (32 °F) 290– 390 at 80 ° C (176 °F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 3 1 2 T R.. Intake air temperature sensor screw 1.2 Nm (0.12 m ·kgf, 0.87 ft ·lbf) Resistance 12.0 at 20 ° C (68 °F) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Injector terminal “1” Negative tester probe Injector terminal “2” 12
haha ELECTRICAL COMPONENTS 8-146 2. Disconnect: Throttle servo motor coupler 3. Check: Throttle servo motor resistance Out of specification Replace the throttle bodies. NOTICE ECA23P1083 Do not disassemble the throttle servo motor. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Connect the pocket tester ( × 1) to the throt- tle servo motor terminal as shown. b. Measure the throttle servo motor resistance. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ 4. Check: Throttle valve operation Throttle valves do not fully close Replace the throttle bodies. ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Connect two C-size batteries to the throttle servo motor terminals “1” as shown. NOTICE ECA23P1084 Do not use a 12 V battery to operate the throt- tle servo motor. TIP Do not use old batteries to operate the throttle servo motor. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ Resistance 0– 100 Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Throttle servo motor terminal “1” Negative tester probe Throttle servo motor terminal “2” 1 2A. Check that the throttle valves “ 2” open. B. Check that the throttle valves “2” fully close. 1 1 2 3V A 1 1 2 3V B
haha 9 TROUBLESHOOTING TROUBLESHOOTING ..................................................................................... 9-1 GENERAL INFORMATION ....................................................................... 9-1 STARTING FAILURES .............................................................................. 9-1 INCORRECT ENGINE IDLING SPEED .................................................... 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 9-2 FAULTY GEAR SHIFTING ........................................................................ 9-2 SHIFT PEDAL DOES NOT MOVE ............................................................ 9-2 JUMPS OUT OF GEAR............................................................................. 9-2 FAULTY CLUTCH ..................................................................................... 9-2 OVERHEATING ........................................................................................ 9-3 OVERCOOLING ........................................................................................ 9-3 POOR BRAKING PERFORMANCE .......................................................... 9-3 FAULTY FRONT FORK LEGS .................................................................. 9-3 UNSTABLE HANDLING ............................................................................ 9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 9-4
haha TROUBLESHOOTING 9-1 EAS28451 TROUBLESHOOTING EAS28460 GENERAL INFORMATION TIP The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, adjustments, and replace- ment of parts. EAS30410 STARTING FAILURES Engine 1. Cylinder(s) and cylinder head Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve 2. Piston(s) and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston 3. Air filter Improperly installed air filter Clogged air filter element 4. Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft Fuel system 1. Fuel tank Empty fuel tank Clogged fuel tank overflow hose Clogged rollover valve Clogged fuel tank breather hose Deteriorated or contaminated fuel Clogged or damaged fuel hose 2. Fuel pump Faulty fuel pump Faulty fuel pump relay 3. Throttle body (-ies) Deteriorated or contaminated fuel Sucked-in air Electrical system 1. Battery Discharged battery Faulty battery 2. Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse 3. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4. Ignition coil(s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils 5. Ignition system Faulty ECU Faulty crankshaft position sensor Broken generator rotor woodruff key 6. Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections 7. Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut-off relay Faulty starter clutch EAS30440 INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder(s) and cylinder head Incorrect valve clearance Damaged valve train components 2. Air filter Clogged air filter element Fuel system 1. Throttle body (-ies) Damaged or loose throttle body joint Improperly synchronized throttle bodies Improper throttle cable free play Flooded throttle body
haha TROUBLESHOOTING 9-2 Electrical system 1. Battery Discharged battery Faulty battery 2. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 3. Ignition coil(s) Broken or shorted primary or secondary coils Cracked or broken ignition coil 4. Ignition system Faulty ECU Faulty crankshaft position sensor Broken generator rotor woodruff key EAS30460 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES ” on page 9-1. Engine 1. Air filter Clogged air filter element Fuel system 1. Throttle body (-ies) Faulty throttle body 2. Fuel pump Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to “ Clutch drags ”. EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28570 FAULTY CLUTCH Clutch slips 1. Clutch Improperly assembled clutch Improperly assembled clutch master cylinder Improperly assembled clutch release cylinder Incorrect clutch fluid level Damaged clutch hose Loose or fatigued clutch spring Loose union bolt Worn friction plate Worn clutch plate Damaged clutch release cylinder 2. Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil Clutch drags 1. Clutch Air in hydraulic clutch system Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Damaged clutch boss Burnt primary driven gear bushing Damaged clutch release cylinder Match marks not aligned 2. Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil
haha TROUBLESHOOTING 9-3 EAS30480 OVERHEATING Engine 1. Clogged coolant passages Cylinder head and piston(s) Heavy carbon buildup 2. Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality Cooling system 1. Coolant Low coolant level 2. Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin 3. Water pump Damaged or faulty water pump Thermostat Thermostat stays closed Hose(s) and pipe(s) Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe Fuel system 1. Throttle body (-ies) Damaged or loose throttle body joint 2. Air filter Clogged air filter element Chassis 1. Brake(s) Dragging brake Electrical system 1. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range 2. Ignition system Faulty ECU EAS28610 OVERCOOLING Cooling system 1. Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent, damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level (high) Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O-ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28690 UNSTABLE HANDLING 1. Handlebar Bent or improperly installed handlebar 2. Steering head components Improperly installed upper bracket Improperly installed lower bracket (improperly tightened ring nut) Bent steering stem Damaged ball bearing or bearing race 3. Front fork leg(s) Uneven oil levels (both front fork legs) Unevenly tensioned fork spring (both front fork legs) Broken fork spring Bent or damaged inner tube Bent or damaged outer tube