Fuel assembly removal

[rd400racer]

I'm trying to get the entire assembly out of the tank on my 2012. There is a small tab about halfway in the assembly that is keeping it from coming out. Is there some trick? The only video I can find is in Italian and it shows him sliding it right out with no problem. Mine won't do that because of the one protruding tab. This shows what I'm talking about

 

[SparrowHawkxx]

Yes, in that video I think that part is cut out where he pushes the tab but notice at 1:14 in the video, he taps on that tab like he is telling you something.

You must press the tab to the side to pull the pump out. It's been I while since I've done this so I don't remember if you push to the left or right, but it will be obvious which way to push. It requires a firm push towards the center, but you don't have to push it very far to get the clearance you need.

 

[rd400racer]

Yes, in that video I think that part is cut out where he pushes the tab but notice at 1:14 in the video, he taps on that tab like he is telling you something.

You must press the tab to the side to pull the pump out. It's been I while since I've done this so I don't remember if you push to the left or right, but it will be obvious which way to push. It requires a firm push towards the center, but you don't have to push it very far to get the clearance you need.

You are the man! Came out with no issues. Everything looks OK, but there was a bit of crud in there. I think I'm getting a new fuel pump since it's apart this far and see if that helps. Thanks so much.

 

[rd400racer]

And I see no reason to have that tab there except to make it harder to get out!

 

[SparrowHawkxx]

And I see no reason to have that tab there except to make it harder to get out!

That was my initial thought also but after thinking about it I thought it must have another purpose.
Now that you have yours out maybe you can check out my idea.
Could this be a stop that catches the float arm?... and the "harder to get out" part is just an added benefit

 

[SparrowHawkxx]

... Everything looks OK, but there was a bit of crud in there. I think I'm getting a new fuel pump since it's apart this far and see if that helps. ....

Like several others, I just replaced the tea bag filter. I replaced it in June 2020 with about 106K miles on the bike.
The tank was clean, a few particles on the filter, not too bad
The Hongwin filter for Yamaha R1/R6 also fits the Super Tenere fuel pump.
2pcs Strainer Fuel Pump Filter Fit Yamaha R1 Yamaha Motorcycle R6//FZ8 | eBay

This thread talks about getting the filter off and back on.
Tea bag fuel filter change | Yamaha Super Tenere Forum

I did not do this but there is also an internal filter that that some have backwashed.

Here are a couple other threads. These are older and have missing pictures so not as useful as they could be.
Replacing/Cleaning the S10 "Tea Bag" fuel filter to restore mileage & power + Guglatech Filter. | Yamaha Super Tenere Forum

Fuel Filters | Yamaha Super Tenere Forum

 

[rd400racer]

OK, back on this again. I replaced the fuel pump and still nothing. The bike will start on starting fluid so that eliminates some of the concerns, but it still will not start on its own. This is really frustrating because I bought this bike for my son as it seemed to be the most reliable Adv bike out there. None of my Beemers have ever failed to start. I'm stumped as where to look at next.

 

[lund]

Starting fluid ........that shit should be illegal to sell, it will "F" up a motor so fast you will hardly have time to blink.
What kind of diagnostics was done to lead you to change the fuel pump?

 

[Jlq1969]

agree with Lund, why replace the fuel pump?….you never said it wouldn't start “before changing the pump”. there are other reasons (electrical and electronic), which prevent it from starting, before the fuel pump

 

[Jlq1969]

To begin with, you should check the error codes on the dash (using the buttons)….check fuse….then take a picture of the timing chain tensioner (to check if it is current or problematic)…..before proceeding trying to start, (if the tensioner is problematic), check the setting of the timing chain…all this after ruling out that the kill switch is in the “on” position

 

[WJBertrand]

Starting fluid ........that shit should be illegal to sell, it will "F" up a motor so fast you will hardly have time to blink.
What kind of diagnostics was done to lead you to change the fuel pump?

I dunno, I’ve used it for years, both for diagnostic procedures and to get a reluctant engine started. Never noticed anything F’d up by it. It’s just a flammable vapor (it will not remain liquid for more than a few seconds once sprayed out of its can). We’re not talking about running the engine extensively on ether. What specific damage do you think it does?


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[rd400racer]

Starting fluid ........that shit should be illegal to sell, it will "F" up a motor so fast you will hardly have time to blink.
What kind of diagnostics was done to lead you to change the fuel pump?

Believe me, I agree on the starting fluid but I wanted to see if it would even fire so as to eliminate a couple of problems. To answer the fuel pump question, I'd say I replaced it simply because I thought I had eliminated all the other problems. I will admit that I'm the worlds worst electrician. This bike ran fine until we came home from a 2 week vacation and then nothing. When it's all said and done, I have a feeling it's going to be something incredibly simple and stupid, but I've pretty much done everything I know to do. I'd already have it in the shop I use but he's booked for a few more weeks.

Sad thing is, I bought this bike for my son believing it was the most problem free of all the big ADV bikes. I've never had one issue with any of my BMW's, but I get him a Yamaha and this happens. Completely frustrating.

 

[rd400racer]

To begin with, you should check the error codes on the dash (using the buttons)….check fuse….then take a picture of the timing chain tensioner (to check if it is current or problematic)…..before proceeding trying to start, (if the tensioner is problematic), check the setting of the timing chain…all this after ruling out that the kill switch is in the “on” position

I had a CBR900RR that had a bad on/off switch. Drove me nuts for a week before I took it to a shop. Guy called me on my way home from dropping it off to come pick it up, he fixed the switch. It's the first thing I check now

 

[SparrowHawkxx]

OK, back on this again. I replaced the fuel pump and still nothing. The bike will start on starting fluid so that eliminates some of the concerns, but it still will not start on its own. This is really frustrating because I bought this bike for my son as it seemed to be the most reliable Adv bike out there. None of my Beemers have ever failed to start. I'm stumped as where to look at next.

This sounds like it could be the well-known hard start problem.
Are you familiar with this? Try searching for some of the solutions to this.
site:yamahasupertenere.com hard start problem - Google Search
site:yamahasupertenere.com WOT - Google Search

You might start with the Wide Open Throttle (WOT) solution.

1. Hold the throttle wide open
2. Push the start button and hold throttle wide open until it starts (or for a reasonable amount of time).

You may also want to jumper the battery to another vehicle to keep the charge up.

Hard start procedure when WOT fails | Yamaha Super Tenere Forum

 

[rd400racer]

This sounds like it could be the well-known hard start problem.
Are you familiar with this? Try searching for some of the solutions to this.
site:yamahasupertenere.com hard start problem - Google Search
site:yamahasupertenere.com WOT - Google Search

You might start with the Wide Open Throttle (WOT) solution.

1. Hold the throttle wide open
2. Push the start button and hold throttle wide open until it starts (or for a reasonable amount of time).

You may also want to jumper the battery to another vehicle to keep the charge up.

Hard start procedure when WOT fails | Yamaha Super Tenere Forum

Yes sir, that's one of the first things I tried after reading about it here. I'm actually trying that after every procedure. I'll probably go home today and try it once more. I keep magically expecting it to start after doing that!

 

[rd400racer]

Funny thing is, my son was all involved in getting this Tenere running until he picked this up last week. Dang kids!

 

[lund]

The Tenere is as simple as it gets.
You replaced the fuel pump, so first thing is when you turn the key "ON" do you hear it?
YES, then it needs to prime up, this takes no more then 10sec at most. If it runs and runs, (the pump) then your having a fuel pressure issue. Most pressure issues are caused by plugged pressure regulator valve screens. Or regulator may be bad but seldom go bad.
NO, your not hearing it, then is there 12v at the pump harness?
NO, check the fuel pump fuse and relay.
If power is at fuse your likely need to replace relay, power goes from fuse to relay.
Thats the basic check.
AND this is IF the fuel system is the issue as a basic check. Hope that helps.
DON'T use starting fluid, I would simply fire my tech if they did that.

 

[Sierra1]

. . . . DON'T use starting fluid, I would simply fire my tech if they did that.

Doesn't true "starter fluid" damage sensors? Maybe sensors that keep the motor from running? If I use a spray to help start a motor, I use a sensor safe cleaning fluid. Does the same thing without risk of damage.

 

[rd400racer]

The Tenere is as simple as it gets.
You replaced the fuel pump, so first thing is when you turn the key "ON" do you hear it?
YES, then it needs to prime up, this takes no more then 10sec at most. If it runs and runs, (the pump) then your having a fuel pressure issue. Most pressure issues are caused by plugged pressure regulator valve screens. Or regulator may be bad but seldom go bad.
NO, your not hearing it, then is there 12v at the pump harness?
NO, check the fuel pump fuse and relay.
If power is at fuse your likely need to replace relay, power goes from fuse to relay.
Thats the basic check.
AND this is IF the fuel system is the issue as a basic check. Hope that helps.
DON'T use starting fluid, I would simply fire my tech if they did that.

Thank you, excellent points. Yes, I can hear the pump motor, so I think that's OK. I've wondered about the fuel flow from the beginning so I'll check that next, and then go through the fuses. Appreciate the advice and I will never use starting fluid again. I used it that one time and barely used any, but never again.

 

[rd400racer]

OK, got some info from the previous owner. I found out the the cam chain tensioner upgrade and the wiring harness recall were both done. He said to check the main starter relay and fuse, that they can be an issue. Problem is that I'm not exactly sure where that is. I know where the fuses are located, so is it in there or close by?