2012 Yamaha XTZ12B(C) Super Tenere Service & Repair Manual (P/N LIT-11616-25-09)

This 2012 Yamaha XTZ12B(C) Super Tenere service manual covers maintenance, diagnosis, and repair for the USA and California versions. Yamaha P/N LIT-11616-25-09, first edition May 2011, carries the additional cover code 23P-28197-10 and is organized into nine chapters.

• Engine repair: Engine removal, crankcase separation, cylinder-head and valve service, piston inspection, camshaft installation, and timing-chain procedures.

• Clutch and driveline: Hydraulic wet-clutch service, transmission disassembly, middle-gear adjustment, final-drive overhaul, and final gear backlash measurement and adjustment.

• Chassis service: Front fork overhaul, steering-head bearings, swingarm and suspension linkage inspection, wheel bearings, and brake caliper and master-cylinder repair.

• Fuel system: Throttle body synchronization, injector inspection, fuel-pressure testing, and throttle and accelerator position-sensor adjustment.

• Cooling system: Radiator removal and cap testing, thermostat inspection, water-pump disassembly, and seal replacement.

• UBS and ABS: Hydraulic-unit operation tests, brake bleeding, warning-light diagnosis, fault-code tables, and post-service checks.

• Electrical diagnosis: YCC-T, TCS, and D-mode explanations, sensor and actuator tests, circuit troubleshooting charts, and complete wiring diagrams.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes an understanding of mechanics and the repair techniques used on these vehicles.

Engine, Clutch, and Shaft Drive

Internal engine work: Procedures cover valve-pad selection, camshaft timing, crankshaft and balancer bearing-clearance checks, and bearing selection. The dry-sump lubrication coverage includes oil-pump inspection and an engine oil lubrication chart.

Driveline setup: Shim-selection formulas, gear-alignment procedures, and thrust-washer checks support final-drive and middle-gear assembly. Tool listings include final gear backlash band 90890-01511 and its U.S. counterpart, middle drive gear lash tool YM-01230. Insufficient final gear backlash can damage the gear teeth.

Specification tables cover engine assembly torques, fluid capacities, clutch wear limits, transmission ratios, chassis dimensions, and frame geometry.

Front Forks, Suspension, and Wheels

Front fork procedures include damper-rod disassembly, seal replacement, and reassembly checks. Rear shock coverage addresses removal, inspection, and replacement; the nitrogen-charged shock is not intended to be opened.

The wheel sections explain how magnetic tools can damage the wheel sensor rotors and impair ABS operation.

Fuel Injection and Throttle Synchronization

Injector installation includes seal checks and a separate pressure test. The synchronization section identifies the white-painted reference bypass screw and explains how disturbing it can cause rough idling and improper throttle-body operation.

California-only procedures cover the evaporative-emissions canister and rollover valves. Cable routing views show the corresponding hose arrangements.

Cooling-System Inspection and Repair

Cooling system diagrams support radiator and hose service, thermostat testing, and water-pump seal and bearing replacement. Radiator-cap pressure testing is documented separately from electrical cooling-fan diagnosis.

UBS and ABS Testing

The ABS block diagram and ABS coupler location chart accompany wheel-sensor, solenoid, motor, and hydraulic-pressure fault tables. ABS faults are read through warning-light flash patterns using test coupler adapter 90890-03149.

The ABS ECU and hydraulic unit are serviced as one assembly and cannot be disassembled. Brake-system work requires the specified bleeding procedure, hydraulic-unit operation tests, and final checks before the motorcycle returns to service.

Electrical and Engine-Control Diagnosis

The multi-function meter's diagnostic mode displays FI fault information and sensor data and supports actuator checks. Fault tables connect a displayed code with wiring, connector, and component checks, helping distinguish a circuit fault from a failed component before replacement.

Starting and charging sections include interlock-circuit troubleshooting, stator and regulator tests, and starter-motor inspection. Lighting, signaling, and fuel-pump circuits have their own troubleshooting charts, with ignition-timing data in the electrical specifications.

A Preview of Engine, Clutch, and Fuel Specifications

These examples represent a small selection of the manual's inspection and test data.

For a warmed engine tested with the throttle wide open, standard compression is 680 kPa at 250 r/min at sea level. Cold intake-valve clearance is 0.10–0.16 mm.

Clutch friction plates 1 and 2 have a standard thickness of 2.92–3.08 mm. The fuel-pump output-pressure specification is 324.0 kPa.

Searchable Text, Bookmarks, and Wiring Sheets

Search and diagram detail: The manual has searchable text and embedded bookmarks for its chapters, major service sections, and wiring diagram. Small labels in the dense circuit diagrams and wiring sheets require zooming.

Supplied as one printable, 606-page PDF in English. The cover, preliminary material, blank pages, rear logo page, wiring-diagram legend, and black-and-white and color wiring sheets are already included in that total.