brake fluid YAMAHA XT1200Z 2012 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
D-mode (drive mode) ......................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-3
Indicator lights and warning lights ............................................3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-15
Handlebar switches ......................3-16
Clutch lever ...................................3-17
Shift pedal .....................................3-18
Brake lever ...................................3-18
Brake pedal ..................................3-19
ABS ..............................................3-20
Traction control system ................3-21
Fuel tank cap ................................3-22
Fuel ...............................................3-23
Fuel tank breather hose and overflow hose ............................3-24
Catalytic converter ........................3-24
Rider seat .....................................3-25
Adjusting the rider seat height ......3-26
Windshield ....................................3-27 Adjusting the front fork ................. 3-28
Adjusting the shock absorber
assembly ................................... 3-30
Carriers ........................................ 3-31
Luggage strap holders ................. 3-32
Sidestand ..................................... 3-32
Ignition circuit cut-off system ........ 3-33
Auxiliary DC jack .......................... 3-35
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Owner ’s tool kit ............................... 6-2
Periodic maintenance chart for the emission control system ............. 6-3
General maintenance and lubrication chart .......................... 6-4
Removing and installing
cowlings ...................................... 6-8
Checking the spark plugs ............. 6-10 Engine oil and oil filter cartridge ... 6-11
Final gear oil ................................ 6-14
Coolant ........................................ 6-15
Air filter element ........................... 6-16
Checking the engine idling
speed ........................................ 6-17
Checking the throttle grip free play ........................................... 6-17
Valve clearance ........................... 6-17
Tires ............................................. 6-18
Spoke wheels .............................. 6-20
Clutch lever .................................. 6-20
Checking the brake lever free play ........................................... 6-20
Brake light switches ..................... 6-21
Checking the front and rear brake pads .......................................... 6-21
Checking the brake fluid level ...... 6-22
Changing the brake and clutch fluids ......................................... 6-23
Checking and lubricating the cables ....................................... 6-24
Checking and lubricating the
throttle grip and cable ............... 6-24
Checking and lubricating the brake and shift pedals .............. 6-24
Checking and lubricating the brake and clutch levers ............ 6-25
Checking and lubricating the
centerstand and sidestand ....... 6-26U23PE2E0.book Page 1 Monday, August 1, 2011 4:25 PM

DESCRIPTION
2-2
2
EAU10420
Right view
2
1
43
85
6
7
9
14 11 13 12 10
1. Rear brake fluid reservoir (page 6-22)
2. Shock absorber assembly spring preload adjusting knob (page 3-30)
3. Front fork rebound damping force adjusting screw (page 3-28)
4. Front fork spring preload adjusting bolt (page 3-28)
5. Main fuse (page 6-29)
6. ABS motor fuse (page 6-29)
7. Fuse box (page 6-29)
8. Front fork compression damping force adjusting screw (page 3-28) 9. Owner
’s tool kit (page 6-2)
10.Battery (page 6-28)
11.Engine oil filler cap (page 6-11)
12.Engine oil level check window (page 6-11)
13.Brake pedal (page 3-19)
14.Shock absorber assembly rebound damping force adjusting knob (page 3-30)U23PE2E0.book Page 2 Monday, August 1, 2011 4:25 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments
87654
321
9
10
1. Clutch lever (page 3-17)
2. Left handlebar switches (page 3-16)
3. Clutch fluid reservoir (page 6-22)
4. Multi-function meter unit (page 3-8)
5. Auxiliary DC jack (page 3-35)
6. Front brake fluid reservoir (page 6-22)
7. Right handlebar switches (page 3-16)
8. Brake lever (page 3-18) 9. Throttle grip (page 6-17)
10.Main switch/steering lock (page 3-3)
U23PE2E0.book Page 3 Monday, August 1, 2011 4:25 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner ’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel 
Check fuel level in fuel tank.
 Refuel if necessary.
 Check fuel line for leakage.
 Check fuel tank breather hose and overflow hose for obstructions, cracks or dam-
age, and check hose connections. 3-23, 3-24
Engine oil 
Check oil level in engine.
 If necessary, add recommended oil to specified level.
 Check vehicle for oil leakage. 6-11
Final gear oil Check vehicle for oil leakage. 6-14
Coolant 
Check coolant level in reservoir.
 If necessary, add recommended coolant to specified level.
 Check cooling system for leakage. 6-15
Front brake 
Check operation.
 If soft or spongy, have Yamaha dealer bleed hydraulic system.
 Check brake pads for wear.
 Replace if necessary.
 Check fluid level in reservoir.
 If necessary, add specified brake fluid to specified level.
 Check hydraulic system for leakage. 6-21, 6-22
U23PE2E0.book Page 1 Monday, August 1, 2011 4:25 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake 
Check operation.
 If soft or spongy, have Yamaha dealer bleed hydraulic system.
 Check brake pads for wear.
 Replace if necessary.
 Check fluid level in reservoir.
 If necessary, add specified brake fluid to specified level.
 Check hydraulic system for leakage. 6-21, 6-22
Clutch 
Check operation.
 If soft or spongy, have Yamaha dealer bleed hydraulic system.
 Check hydraulic system for leakage. 6-20
Throttle grip 
Make sure that operation is smooth.
 Check throttle grip free play.
 If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 6-17, 6-24
Control cables 
Make sure that operation is smooth.
 Lubricate if necessary. 6-24
Wheels and tires 
Check for damage.
 Check tire condition and tread depth.
 Check air pressure.
 Correct if necessary. 6-18, 6-20
Brake and shift pedals 
Make sure that operation is smooth.
 Lubricate pedal pivoting points if necessary. 6-24
Brake and clutch levers 
Make sure that operation is smooth.
 Lubricate lever pivoting points if necessary. 6-25
Centerstand, sidestand 
Make sure that operation is smooth.
 Lubricate pivots if necessary. 6-26
Chassis fasteners 
Make sure that all nuts, bolts and screws are properly tightened.
 Tighten if necessary. —
Instruments, lights, signals
and switches 
Check operation.
 Correct if necessary. —
ITEM CHECKS PAGE
U23PE2E0.book Page 2 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 *Air filter element Replace. √
2 *Clutch 
Check operation, fluid level and
vehicle for fluid leakage. √√√√√
3 *Front brake 
Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
 Replace brake pads. Whenever worn to the limit
4 *Rear brake 
Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
 Replace brake pads. Whenever worn to the limit
5 *Brake hoses 
Check for cracks or damage.
 Check for correct routing and
clamping. √√√√√
 Replace. Every 4 years
6 *Wheels 
Check runout, spoke tightness
and for damage.
 Tighten spokes if necessary. At the initial 1000 km (600 mi) and every 5000 km (3000 mi) thereafter.
7 *Tires 
Check tread depth and for dam-
age.
 Replace if necessary.
 Check air pressure.
 Correct if necessary. √√√√√
8 *Wheel bearings 
Check bearing for looseness or
damage. √√√√
U23PE2E0.book Page 4 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU36771
TIP

Air filter This model ’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
 The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.


Hydraulic brake and clutch service
 Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.
 Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master
and release cylinders, and change the brake and clutch fluids.
 Replace the brake and clutch hoses every four years and if cracked or damaged.
U23PE2E0.book Page 7 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6
the point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU40261
Checking the brake fluid level Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
Rear brake
WARNING
EWA16010
Improper maintenance can result in
loss of braking ability. Observe
these precautions:

Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.


Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
1. Lining thickness
11
1. Minimum level mark
LOWER
1
1. Minimum level mark
Specified brake fluid:
DOT 4
UPPER
LOWER
1
U23PE2E0.book Page 22 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6


Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.


Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.


Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re-
sult in vapor lock, and dirt may
clog the ABS hydraulic unit
valves.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brakefluid level goes down suddenly, have a
Yamaha dealer check the cause before further riding.
EAU22751
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the TIP after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake and clutch hoses: Replace
every four years.
U23PE2E0.book Page 23 Monday, August 1, 2011 4:25 PM

SPECIFICATIONS
8-2
8
Secondary reduction ratio:2.987 (21/25 x 32/9)
Transmission type: Constant mesh 6-speed
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)
5th: 1.042 (25/24)
6th: 0.929 (26/28)Chassis:Frame type:Backbone
Caster angle: 28.00 °
Trail:
126 mm (5.0 in)Front tire:Type:Tubeless
Size:
110/80R19M/C 59V
Manufacturer/model: BRIDGESTONE/BW501 Manufacturer/model:
METZELER/TOURANCE EXP C
Rear tire:Type:
Tubeless
Size: 150/70R17M/C 69V
Manufacturer/model: BRIDGESTONE/BW502
Manufacturer/model:
METZELER/TOURANCE EXP CLoading:Maximum load:209 kg (461 lb)
(Total weight of rider, passenger, cargo and
accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0 –198 lb)
Front: 225 kPa (2.25 kgf/cm ², 33 psi)
Rear: 250 kPa (2.50 kgf/cm ², 36 psi)
Loading condition:
90– 209 kg (198 –461 lb)
Front: 225 kPa (2.25 kgf/cm ², 33 psi)
Rear: 290 kPa (2.90 kgf/cm ², 42 psi)Front wheel:Wheel type:
Spoke wheel Rim size:
19M/C x MT2.50
Rear wheel:Wheel type:
Spoke wheel
Rim size: 17M/C x MT4.00Unified brake system:Operation:
Activated by front brakeFront brake:Type:Dual disc brake
Operation:
Right hand operation
Specified brake fluid: DOT 4Rear brake:Type:
Single disc brake
Operation: Right foot operation
Specified brake fluid: DOT 4Front suspension:Type:Telescopic fork
Spring/shock absorber type: Coil spring/oil damper
Wheel travel:
190.0 mm (7.48 in)Rear suspension:Type:Swingarm (link suspension)
U23PE2E0.book Page 2 Monday, August 1, 2011 4:25 PM