2012 Na Yamaha Super Tenere Manual

							
haha 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS ........................................................................ 2-10
ELECTRICAL SPECIFICATIONS ................................................................. 2-13
TIGHTENING TORQUES .............................................................................. 2-16
GENERAL TIGHTENING TORQUE SPECIFICATIONS ......................... 2-16
ENGINE TIGHTENING TORQUES ......................................................... 2-17
CHASSIS TIGHTENING TORQUES ....................................................... 2-22
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-28
ENGINE ................................................................................................... 2-28
CHASSIS ........................................................................\
......................... 2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS .................................... 2-31
ENGINE OIL LUBRICATION CHART ..................................................... 2-31
LUBRICATION DIAGRAMS .................................................................... 2-33
COOLING SYSTEM DIAGRAMS .................................................................. 2-41
CABLE ROUTING ......................................................................................... 2-43  
						

							
haha GENERAL SPECIFICATIONS
2-1
EAS20280
GENERAL SPECIFICATIONS
Model Model 23P4 (USA)
23P5 (California)
Dimensions Overall length 2255 mm (88.8 in)
Overall width 980 mm (38.6 in)
Overall height 1410 mm (55.5 in)
Seat height 845 mm (33.3 in) (low position)
870 mm (34.3 in) (high position)
Wheelbase 1540 mm (60.6 in)
Ground clearance 205 mm (8.07 in)
Minimum turning radius 2700 mm (106.3 in)
Weight Curb weight 261 kg (575 lb) (USA)
262 kg (578 lb) (California)
Maximum load (total weight of rider, passenger,  cargo and accessories) 209 kg (461 lb) (USA)
208 kg (459 lb) (California)  
						

							
haha ENGINE SPECIFICATIONS
2-2
EAS20290
ENGINE SPECIFICATIONS
Engine Engine type Liquid cooled 4-stroke, DOHC
Displacement 1199 cm³
Cylinder arrangement Inline 2-cylinder
Bore  × stroke 98.0 × 79.5 mm (3.86  × 3.13 in)
Compression ratio 11.00 :1
Standard compression pressure (at sea level) 680 kPa/250 r/min (6.8 kgf/cm ²/250 r/min, 96.7 
psi/250 r/min)
Minimum –maximum 590– 760 kPa (5.9–7.6 kgf/cm², 83.9 –108.1 psi)
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 23.0 L (6.08 US gal, 5.06 Imp.gal)
Fuel reserve amount 3.9 L (1.03 US gal, 0.86 Imp.gal)
Engine oilLubrication system Dry sump
Recommended brand YAMALUBE
Type SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard 
MA
Engine oil quantity Total amount 4.20 L (4.44 US qt, 3.70 Imp.qt)
Without oil filter cartridge replacement 3.10 L (3.28 US qt, 2.73 Imp.qt)
With oil filter cartridge replacement 3.40 L (3.59 US qt, 2.99 Imp.qt)
Oil pressure 65.0 kPa/1100 r/min (0.65 kgf/cm²/1100 r/min, 
9.4 psi/1100 r/min) at oil temperature of 65.0 –
75.0  °C (149.00 –167.00 ° F)
Final gear oil
Type Yamaha genuine shaft drive gear oil SAE 80 API 
GL-5 or SAE 80 API GL-4 Hypoid gear oil
Quantity 0.20 L (0.21 US qt, 0.18 Imp.qt)
Oil filter
Oil filter type Cartridge
Bypass valve opening pressure 80.0 –120.0 kPa (0.80– 1.20 kgf/cm², 11.6 –17.4 
psi)
Oil pump Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.120 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09 –0.19 mm (0.0035 –0.0075 in)
Limit 0.26 mm (0.0102 in)
Oil-pump-housing-to-inner-and-outer-rotor  clearance (oil feed pump) 0.03 –0.08 mm (0.0012 –0.0032 in)
Limit 0.15 mm (0.0059 in)  
						

							
haha ENGINE SPECIFICATIONS
2-3
Oil-pump-housing-to-inner-and-outer-rotor  clearance (scavenging pump) 0.06– 0.13 mm (0.0024–0.0051 in)
Limit 0.20 mm (0.0079 in)
Relief valve operating pressure 540.0–660.0 kPa (5.40– 6.60 kgf/cm², 78.3 –95.7 
psi)
Cooling system Radiator capacity (including all routes) 1.83 L (1.93 US qt, 1.61 Imp.qt)
Coolant reservoir capacity (up to the maximum level mark) 0.26 L (0.27 US qt, 0.23 Imp.qt)
Radiator cap opening pressure 93.3 –122.7 kPa (0.93– 1.23 kgf/cm², 13.5 –17.8 
psi)
Thermostat Valve opening temperature 69.0–73.0 °C (156.2 –163.4 ° F)
Valve full open temperature 84.0 °C (183.20  °F)
Valve lift (full open) 8.0 mm (0.31 in)
Radiator core Width 171.4 mm (6.75 in)
Height 320.0 mm (12.60 in)
Depth 22.0 mm (0.87 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 48/48 (1.000)
Impeller shaft tilt limit 0.15 mm (0.0059 in)
Spark plug(s)
Manufacturer/model NGK/CPR8EB9
Spark plug gap 0.8–0.9 mm (0.031– 0.035 in)
Cylinder head
Volume 50.17–51.57 cm ³ (3.06 –3.15 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (right)
Camshaft cap inside diameter 24.500 –24.521 mm (0.9646 –0.9654 in)
Camshaft journal diameter 24.459 –24.472 mm (0.9630 –0.9635 in)
Camshaft-journal-to-camshaft-cap clearance 0.028 –0.062 mm (0.0011– 0.0024 in)
Camshaft lobe dimensions Intake A 40.250–40.350 mm (1.5846 –1.5886 in)
Limit 40.150 mm (1.5807 in)
Intake B 29.976–30.076 mm (1.1802 –1.1841 in)
Limit 29.876 mm (1.1762 in)
Exhaust A 39.250–39.350 mm (1.5453 –1.5492 in)
Limit 39.150 mm (1.5413 in)
Exhaust B 29.950–30.050 mm (1.1791 –1.1831 in)   
						

							
haha ENGINE SPECIFICATIONS
2-4
Limit 29.850 mm (1.1752 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Timing chain Tensioning system Automatic
Valve, valve seat, valve guideValve clearance (cold) Intake 0.10–0.16 mm (0.0039 –0.0063 in)
Exhaust 0.22–0.28 mm (0.0087 –0.0110 in)
Valve dimensions Valve head diameter A (intake) 36.90– 37.10 mm (1.4528–1.4606 in)
Valve head diameter A (exhaust) 30.90 –31.10 mm (1.2165– 1.2244 in)
Valve face width B (intake) 2.050 –2.480 mm (0.0807– 0.0976 in)
Valve face width B (exhaust) 2.050 –2.480 mm (0.0807– 0.0976 in)
Valve seat width C (intake) 1.10 –1.30 mm (0.0433 –0.0512 in)
Valve seat width C (exhaust) 0.90 –1.10 mm (0.0354 –0.0433 in)
Valve margin thickness D (intake) 1.00 –1.40 mm (0.0394 –0.0551 in)
Valve margin thickness D (exhaust) 1.00 –1.40 mm (0.0394 –0.0551 in)
Valve stem diameter (intake) 5.475 –5.490 mm (0.2156– 0.2161 in)
Limit 5.445 mm (0.2144 in)
A
B
A
B
C
D   
						

							
haha ENGINE SPECIFICATIONS
2-5
Valve stem diameter (exhaust) 5.460–5.475 mm (0.2150– 0.2156 in)
Limit 5.430 mm (0.2138 in)
Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165– 0.2170 in)
Limit 5.550 mm (0.2185 in)
Valve guide inside diameter (exhaust) 5.500–5.512 mm (0.2165– 0.2170 in)
Limit 5.550 mm (0.2185 in)
Valve-stem-to-valve-guide clearance (intake) 0.010 –0.037 mm (0.0004– 0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025 –0.052 mm (0.0010– 0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 40.22 mm (1.58 in)
Limit 38.21 mm (1.50 in)
Free length (exhaust) 40.22 mm (1.58 in)
Limit 38.21 mm (1.50 in)
Installed length (intake) 32.00 mm (1.26 in)
Installed length (exhaust) 32.00 mm (1.26 in)
Spring rate K1 (intake) 25.00 N/mm (2.55 kgf/mm, 142.75 lb/in)
Spring rate K2 (intake) 32.53 N/mm (3.32 kgf/mm, 185.75 lb/in)
Spring rate K1 (exhaust) 25.00 N/mm (2.55 kgf/mm, 142.75 lb/in)
Spring rate K2 (exhaust) 32.53 N/mm (3.32 kgf/mm, 185.75 lb/in)
Installed compression spring force (intake) 192.00 –220.00 N (19.58 –22.43 kgf, 43.16 –
49.46 lbf)
Installed compression spring force (exhaust) 192.00 –220.00 N (19.58 –22.43 kgf, 43.16 –
49.46 lbf)
Spring tilt (intake) 2.5° /1.8 mm (2.5°/0.07 in)
Spring tilt (exhaust) 2.5 °/1.8 mm (2.5° /0.07 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder Bore 98.000–98.010 mm (3.8583 –3.8587 in)
Taper limit 0.05 mm (0.002 in)
Out of round limit 0.05 mm (0.002 in)
Piston Piston-to-cylinder clearance 0.020 –0.045 mm (0.0008– 0.0018 in)
Limit 0.15 mm (0.0059 in)  
						

							
haha ENGINE SPECIFICATIONS
2-6
Diameter D 97.965–97.980 mm (3.8569 –3.8575 in)
Height H 8.0 mm (0.31 in)
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 22.004 –22.015 mm (0.8663 –0.8667 in)
Limit 22.045 mm (0.8679 in)
Piston pin outside diameter 21.991 –22.000 mm (0.8658 –0.8661 in)
Limit 21.971 mm (0.8650 in)
Piston-pin-to-piston-pin-bore clearance 0.004 –0.024 mm (0.00016 –0.00094 in)
Piston ring
Top ring Ring type Barrel
Dimensions (B ×  T) 1.20 × 3.45 mm (0.05  × 0.14 in)
End gap (installed) 0.20–0.35 mm (0.0079 –0.0138 in)
Limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.070 mm (0.0012– 0.0028 in)
Limit 0.120 mm (0.0047 in)
2nd ring
Ring type Taper
Dimensions (B ×  T) 1.20 × 4.20 mm (0.04  × 0.17 in)
End gap (installed) 0.35–0.50 mm (0.0138 –0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.060 mm (0.0008– 0.0024 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Dimensions (B ×  T) 2.00 × 2.65 mm (0.08  × 0.10 in)
End gap (installed) 0.20–0.70 mm (0.0079 –0.0276 in)
Connecting rod
Oil clearance 0.029–0.053 mm (0.0011– 0.0021 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green
H
D
T
B
B
T
B
T  
						

							
haha ENGINE SPECIFICATIONS
2-7
Crankshaft Width A 165.60–166.40 mm (6.520– 6.551 in)
Width B 67.75–68.25 mm (2.67 –2.69 in)
Runout limit C 0.020 mm (0.0008 in)
Big end side clearance D 0.160 –0.262 mm (0.0063– 0.0103 in)
Journal oil clearance 0.020 –0.044 mm (0.0008– 0.0017 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow
Balancer Balancer drive method Gear
Balancer shaft-journal-to-balancer shaft-journal-bearing clearance 0.016– 0.040 mm (0.0006–0.0016 in)
Clutch
Clutch type Wet, multiple-disc
Clutch release method Hydraulic inner push
Friction plate 1, 2 thickness 2.92 –3.08 mm (0.115 –0.121 in)
Wear limit 2.82 mm (0.1110 in)
Plate quantity 8 pcs
Friction plate 3 thickness 2.90– 3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1110 in)
Plate quantity 1 pc
Clutch plate thickness 1.90 –2.10 mm (0.075 –0.083 in)
Plate quantity 8 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring height 6.78 mm (0.27 in)
Minimum height 6.44 mm (0.25 in)
Spring quantity 1 pc
Long clutch push rod bending limit 0.2 mm (0.0079 in)
Transmission Transmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 1.466 (85/58)
Final drive Shaft
Secondary reduction ratio 2.987 (21/25  × 32/9)
Operation Left foot operation
Gear ratio 1st 2.769 (36/13)
2nd 2.063 (33/16)
3rd 1.571 (33/21)
4th 1.250 (30/24)   
						

							
haha ENGINE SPECIFICATIONS
2-8
5th 1.042 (25/24)
6th 0.929 (26/28)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork guide bar bending limit 0.100 mm (0.0039 in)
Shift fork thickness 6.26 –6.39 mm (0.2465 –0.2516 in)
Air filter
Air filter element Oil-coated paper element
Fuel pumpPump type Electrical
Output pressure 324.0 kPa (3.24 kgf/cm ², 47.0 psi)
Fuel injector
Model/quantity 297500– 0820/2
Resistance 12.0  at 20 °C (68  °F)
Throttle body
Type/quantity 46EIS/2
ID mark 23P1 00 (USA)
23P5 20 (California)
Throttle position sensor Resistance 1.20–2.80 k 
Output voltage (at idle) 0.63 –0.73 V
Accelerator position sensor
Resistance 1.20–2.80 k 
Output voltage 0.63– 0.73 V
Fuel injection sensor
Crankshaft position sensor resistance 336 –504   at 20  °C (68  °F)
Intake air pressure sensor output voltage 3.57 –3.71 V at 101.3 kPa
Intake air temperature sensor resistance 5.40 –6.60 k  at 0  °C (32  °F)
290– 390   at 80  °C (176  °F)
Coolant temperature sensor resistance 5.21– 6.37 k at 0  °C (32  °F)
290– 354  at 80  °C (176  °F)
Idling condition
Engine idling speed 1050– 1150 r/min
Intake vacuum 35.3– 39.3 kPa (265–295 mmHg, 10.4 –11.6 
inHg)
Water temperature 85.0–105.0 ° C (185.00 –221.00 ° F)
Oil temperature 65.0–75.0  °C (149.00 –167.00 ° F)
Throttle cable free play 3.0–5.0 mm (0.12– 0.20 in)
Shaft drive
Middle gear backlash 0.045–0.090 mm (0.002– 0.004 in)
Ring-gear-to-stopper-bolt clearance 0.30–0.60 mm (0.012 –0.024 in)  
						

							
haha ENGINE SPECIFICATIONS
2-9
Ring-gear-to-thrust-washer clearance 0.10–0.20 mm (0.004 –0.008 in)
Final gear backlash 0.20–0.40 mm (0.008 –0.016 in)