2012 – 2013 Yamaha XTZ12B Super Tenere Motorcycle Repair Service Manual

Description

This Official 2012 – 2013 Yamaha XTZ12 Super Tenere Motorcycle Repair and Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for:

2012 Yamaha XTZ12 Super Tenere motorcycles
2013  Yamaha XTZ12 Super Tenere motorcycles

Table of Contents

General Information
Specifications
Periodic Checks And Adjustments
Chassis
Engine
Cooling System
Fuel System
Electrical System
Troubleshooting

Index of Topics

Chapter 1 General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline Of The FI System
FI System
YCC-T (yamaha Chip Controlled Throttle)
Outline Of The UBS
Outline Of The ABS
ABS Component Functions
UBS And ABS Operation
ABS Self-diagnosis Function
ABS Warning Light And Operation
Outline Of The TCS (traction Control System)
Instrument Functions
Important Information
Preparation For Removal And Disassembly
Replacement Parts
Gaskets, Oil Seals And O-rings
Lock Washers/plates And Cotter Pins
Bearings And Oil Seals
Circlips
Basic Service Information
Quick Fasteners
Electrical System
Special Tools

Chapter  2 Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points And Lubricant Types
Engine
Chassis
Lubrication System Chart And Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cooling System Diagrams
Cable Routing

Chapter  3 Periodic Checks And Adjustments
Periodic Maintenance
Introduction
Periodic Maintenance Chart For The Emission
Control System
General Maintenance And Lubrication Chart
Checking The Fuel Line
Checking The Spark Plugs
Adjusting The Valve Clearance
Checking The Cylinder Head Breather Hose
Synchronizing The Throttle Bodies
Checking The Exhaust System
Checking The Canister (for California Only)
Replacing The Air Filter Element
Adjusting The Clutch Lever
Checking The Clutch Fluid Level
Bleeding The Hydraulic Clutch System
Adjusting The Front Disc Brake
Checking The Brake Fluid Level
Bleeding The Hydraulic Brake System (abs)
Checking The Front Brake Pads
Checking The Rear Brake Pads
Checking The Brake Hoses
Checking The Wheels
Checking And Tightening The Spokes
Checking The Tires
Checking The Wheel Bearings
Checking The Swingarm Pivot
Lubricating The Swingarm Pivot
Checking And Adjusting The Steering Head
Lubricating The Steering Head
Checking The Fasteners
Lubricating The Levers
Lubricating The Pedals
Checking The Sidestand
Checking The Centerstand
Lubricating The Sidestand
Lubricating The Centerstand
Checking The Sidestand Switch
Checking The Front Fork
Adjusting The Front Fork Legs
Checking The Rear Suspension
Adjusting The Rear Shock Absorber Assembly
Checking The Engine Oil Level
Changing The Engine Oil
Measuring The Engine Oil Pressure
Checking The Coolant Level
Checking The Cooling System
Changing The Coolant
Checking The Final Gear Oil Level
Changing The Final Gear Oil
Checking The Brake Light Switches
Adjusting The Rear Brake Light Switch
Checking And Lubricating The Cables
Checking The Throttle Grip Operation
Checking The Switches, Lights And Signals
Adjusting The Headlight Beams
Replacing The Headlight Bulbs
Replacing The Auxiliary Light Bulbs

Chapter 4 Chassis
General Chassis
Installing The Seats
Installing The Carriers
Removing The Abs Unit Cover
Installing The Abs Unit Cover
Removing The Side Cowlings
Installing The Side Cowlings
Installing The Electrical Components Tray
Assembling The Headlight
Installing The Headlight Assembly And Windshield
Removing The Air Filter Case
Front Wheel
Removing The Front Wheel
Disassembling The Front Wheel
Checking The Front Wheel
Maintenance Of The Front Wheel Sensor And
Sensor Rotor
Assembling The Front Wheel
Adjusting The Front Wheel Static Balance
Installing The Front Wheel (front Brake Discs)
Rear Wheel
Removing The Rear Wheel
Disassembling The Rear Wheel
Checking The Rear Wheel
Maintenance Of The Rear Wheel Sensor And
Sensor Rotor
Assembling The Rear Wheel
Adjusting The Rear Wheel Static Balance
Installing The Rear Wheel (rear Brake Disc)
Front Brake
Introduction
Checking The Front Brake Discs
Replacing The Front Brake Pads
Removing The Front Brake Calipers
Disassembling The Front Brake Calipers
Checking The Front Brake Calipers
Assembling The Front Brake Calipers
Installing The Front Brake Calipers
Removing The Front Brake Master Cylinder
Checking The Front Brake Master Cylinder
Assembling The Front Brake Master Cylinder
Installing The Front Brake Master Cylinder
Rear Brake
Introduction
Checking The Rear Brake Disc
Replacing The Rear Brake Pads
Removing The Rear Brake Caliper
Disassembling The Rear Brake Caliper
Checking The Rear Brake Caliper
Assembling The Rear Brake Caliper
Installing The Rear Brake Caliper
Removing The Rear Brake Master Cylinder
Disassembling The Rear Brake Master Cylinder
Checking The Rear Brake Master Cylinder
Assembling The Rear Brake Master Cylinder
Installing The Rear Brake Master Cylinder
Abs (anti-lock Brake System)
Removing The Hydraulic Unit Assembly
Checking The Hydraulic Unit Assembly
Checking The Brake Pipes
Installing The Hydraulic Unit Assembly
Hydraulic Unit Operation Tests
Trial Run
Handlebar
Removing The Handlebar
Checking The Handlebar
Installing The Handlebar
Front Fork
Removing The Front Fork Legs
Disassembling The Front Fork Legs
Checking The Front Fork Legs
Assembling The Front Fork Legs
Installing The Front Fork Legs
Steering Head
Removing The Lower Bracket
Checking The Steering Head
Installing The Steering Head
Rear Shock Absorber Assembly
Handling The Rear Shock Absorber
Disposing Of A Rear Shock Absorber
Removing The Rear Shock Absorber Assembly
Checking The Rear Shock Absorber Assembly
Checking The Connecting Arm And Relay Arm
Installing The Relay Arm
Installing The Rear Shock Absorber Assembly
Swingarm
Removing The Swingarm
Checking The Swingarm
Installing The Swingarm
Shaft Drive
Troubleshooting
Checking The Final Drive Oil For Contamination And
Checking The Shaft Drive For Leaks
Measuring The Final Gear Backlash
Adjusting The Final Gear Backlash
Measuring The Ring-gear-to-stopper-bolt
Clearance
Adjusting The Ring-gear-to-stopper-bolt
Clearance
Disassembling The Final Drive Assembly
Removing And Installing The Bearings
Assembling The Final Drive Assembly
Aligning The Final Drive Pinion Gear And Ring
Gear
Checking The Drive Shaft
Installing The Drive Shaft And Final Drive Assembly

Chapter  5 Engine
Engine Inspection
Measuring The Compression Pressure
Engine Removal
Removing The Engine
Installing The Engine
Installing The Exhaust Pipe And Muffler
Camshafts
Removing The Cylinder Head Cover
Removing The Camshafts
Checking The Camshafts
Checking The Camshaft Sprocket
Checking The Timing Chain Tensioners
Checking The Decompression System
Installing The Camshafts
Installing The Cylinder Head Cover
Cylinder Head
Removing The Cylinder Head
Checking The Timing Chain Guide (exhaust Side)
Checking The Cylinder Head
Installing The Cylinder Head
Valves And Valve Springs
Removing The Valves
Checking The Valves And Valve Guides
Checking The Valve Seats
Checking The Valve Springs
Checking The Valve Lifters
Installing The Valves
Cylinder And Pistons
Removing The Pistons
Checking The Cylinders And Pistons
Checking The Piston Rings
Checking The Piston Pins
Installing The Pistons And Cylinder
Generator And Starter Clutch
Removing The Generator
Removing The Starter Clutch
Checking The Starter Clutch
Checking The Torque Limiter
Installing The Starter Clutch
Installing The Generator
Electric Starter
Checking The Starter Motor
Assembling The Starter Motor
Clutch
Removing The Clutch
Checking The Friction Plates
Checking The Clutch Plates
Checking The Clutch Spring Plate
Checking The Clutch Housing
Checking The Clutch Boss
Checking The Pressure Plate
Checking The Clutch Push Rods
Checking The Primary Driven Gear
Installing The Clutch
Disassembling The Clutch Master Cylinder
Checking The Clutch Master Cylinder
Assembling The Clutch Master Cylinder
Installing The Clutch Master Cylinder
Removing The Clutch Release Cylinder
Assembling The Clutch Release Cylinder
Installing The Clutch Release Cylinder
Pickup Rotor
Removing The Pickup Rotor
Installing The Pickup Rotor
Shift Shaft
Checking The Shift Shaft
Checking The Stopper Lever
Installing The Shift Shaft
Adjusting The Shift Pedal
Oil Pump
Removing The Oil Pan And Oil Strainer Cover
Checking The Oil Pump
Checking The Relief Valve
Checking The Oil Pipe
Checking The Oil Strainer
Assembling The Oil Pump
Installing The Oil Pan
Installing The Oil Strainer Cover
Crankcase
Removing The Rear Balancer
Disassembling The Crankcase
Checking The Crankcase
Checking The Rear Balancer
Checking The Timing Chain And Timing Chain Guide
(intake Side)
Checking The Oil Nozzles
Assembling The Crankcase
Installing The Rear Balancer
Crankshaft And Balancer
Removing The Front Balancer Shaft
Removing The Balancer Shaft Journal Bearings
Removing The Crankshaft Journal Bearings
Removing The Connecting Rods
Checking The Crankshaft
Checking The Connecting Rods
Checking The Front Balancer
Installing The Connecting Rods
Installing The Crankshaft
Installing The Front Balancer Shaft
Transmission
Removing The Transmission
Checking The Shift Forks
Checking The Shift Drum Assembly
Checking The Transmission
Assembling The Main Axle And Drive Axle
Installing The Transmission
Middle Gear
Removing The Middle Driven Pinion Gear Assembly
Disassembling The Middle Driven Pinion Gear
Assembly
Removing The Middle Drive Pinion Gear Assembly
Disassembling The Middle Drive Pinion Gear
Assembly
Checking The Middle Driven Pinion Gear Assembly
Checking The Middle Drive Pinion Gear Assembly
Assembling The Middle Drive Pinion Gear Assembly
Installing The Middle Drive Pinion Gear Assembly
Assembling The Middle Driven Pinion Gear Assembly
Installing The Middle Driven Pinion Gear Assembly
Measuring The Middle Gear Backlash
Adjusting The Middle Gear Backlash
Aligning The Middle Gear

 

Chapter 6 Cooling System
Radiator
Checking The Radiator
Installing The Radiator
Thermostat
Checking The Thermostat
Installing The Thermostat
Water Pump
Disassembling The Water Pump
Checking The Water Pump
Assembling The Water Pump
Installing The Water Pump

Chapter 7 Fuel System
Fuel Tank
Removing The Fuel Tank
Removing The Fuel Pump
Checking The Fuel Pump Body
Checking The Rollover Valves (for California Only)
Installing The Fuel Pump
Installing The Fuel Tank
Throttle Bodies
Checking The Injectors (before Removing)
Removing The Injectors
Checking The Injectors
Checking And Cleaning The Throttle Bodies
Checking The Throttle Body Joints
Installing The Injectors
Checking The Injector Pressure
Checking The Fuel Pressure
Adjusting The Throttle Position Sensor
Adjusting The Accelerator Position Sensor
Installing The Throttle Body Joints

Chapter 8 Electrical System
Ignition System
Circuit Diagram
Engine Stopping Due To Sidestand Operation
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-off System Operation
Troubleshooting
Charging System
Circuit Diagram

Chapter 9 Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Signaling System
Circuit Diagram
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Injection System
Circuit Diagram
Ecu Self-diagnostic Function
Troubleshooting Method
Diagnostic Mode
Troubleshooting Details
Diagnostic Code Table
Fuel Pump System
Circuit Diagram
Troubleshooting
Troubleshooting
General Information
Starting Failures
Incorrect Engine Idling Speed
Poor Medium-and-high-speed Performance
Faulty Gear Shifting
Shift Pedal Does Not Move
Jumps Out Of Gear
Faulty Clutch
Overheating
Overcooling
Poor Braking Performance
Faulty Front Fork Legs
Unstable Handling
Faulty Lighting Or Signaling System