brake YAMAHA XT1200Z 2010 User Guide

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 recommended 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 cable free play.
 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing. 6-17, 6-24
Control cables 
Make sure that operation is smooth.
 Lubricate if necessary. 6-23
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. 6-25
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
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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. √√√√√
 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. √√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
9*Swingarm 
Check operation and for exces-
sive play. √√√√
 Lubricate with lithium-soap-based
grease. Every 50000 km (30000 mi)
10 *Steering bearings 
Check bearing play and steering
for roughness. √√√√√
 Lubricate with lithium-soap-based
grease. Every 50000 km (30000 mi)
11 *Chassis fasteners 
Make sure that all nuts, bolts and
screws are properly tightened. √√√√√
12 Brake lever pivot
shaft 
Lubricate with silicone grease. √√√√√
13 Brake pedal pivot
shaft 
Lubricate with lithium-soap-based
grease. √√√√√
14 Clutch lever pivot
shaft

Lubricate with silicone grease. √√√√√
15 Shift pedal pivot
shaft 
Lubricate with lithium-soap-based
grease. √√√√√
16 Sidestand, center-
stand 
Check operation.
 Lubricate with lithium-soap-based
grease. √√√√√
17 *Sidestand switch Check operation. √√√√√√
18 *Front fork 
Check operation and for oil leak-
age. √√√√
19 *Shock absorber as-
sembly 
Check operation and shock ab-
sorber for oil leakage. √√√√
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
20*Rear suspension re-
lay arm and con-
necting arm
pivoting points 
Check operation. √√√√
21 Engine oil 
Change.
 Check oil level and vehicle for oil
leakage. √√√√√√
22 Engine oil filter car-
tridge 
Replace. √√√
23 *Cooling system 
Check coolant level and vehicle
for coolant leakage. √√√√√
 Change. Every 3 years
24 Final gear oil 
Check oil level and vehicle for oil
leakage. √√ √
 Change. √√√
25 *Front and rear brake
switches

Check operation. √√√√√√
26 Moving parts and
cables

Lubricate. √√√√√
27 *Throttle grip hous-
ing and cable 
Check operation and free play.
 Adjust the throttle cable free play
if necessary.
 Lubricate the throttle grip housing
and cable. √√√√√
28 *Lights, signals and
switches 
Check operation.
 Adjust headlight beam. √√√√√√
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)U23PE0E0.book Page 6 Wednesday, March 3, 2010 2:29 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
WARNING
EWA10471


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.


The replacement of all wheel
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the necessary professional knowl-
edge and experience to do so.


Ride at moderate speeds after
changing a tire since the tire
surface must first be “ broken
in ” for it to develop its optimal
characteristics.
Tire information
This motorcycle is equipped with spoke
wheels and tubeless tires with valves.
WARNING
EWA10901


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle may be different, which
could lead to an accident.


Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.


Use only the tire valves and
valve cores listed below to
avoid tire deflation during a ride.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Front tire: Size: 110/80R19M/C 59V
Manufacturer/model: BRIDGESTONE/BW501
METZELER/TOURANCE EXP C
Rear tire: Size: 150/70R17M/C 69V
Manufacturer/model: BRIDGESTONE/BW502
METZELER/TOURANCE EXP C
FRONT and REAR: Tire air valve: TR412
Va l ve c o r e : #9100 (original)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
EAU49710
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
EAU42850
Clutch lever Since this model is equipped with a hy-
draulic clutch, adjusting the clutch lever
free play is not needed. However, it is
necessary to check the hydraulic sys-
tem for leakage before each ride. If the
clutch lever free play does become ex-
cessive, and shifting becomes rough or
clutch slippage occurs, causing poor
acceleration, there may be air in the
clutch system. If there is air in the hy-
draulic system, have a Yamaha dealer
bleed the system before operating the
motorcycle.
EAU37913
Checking the brake lever free
play There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be- fore operating the vehicle. Air in the
hydraulic system will diminish the1. No brake lever free play
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
braking performance, which may re-
sult in loss of control and an acci-
dent.
EAU36503
Brake light switches The brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, have a Yamaha deal-
er adjust the brake light switches.
EAU22392
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36890
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn to1. Brake pad wear indicator
1
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6the 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.
EAU40260
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective. Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
1. Lining thickness
11
1. Minimum level mark
1. Minimum level mark
LOWER
1
UPPER
LOWER
1
Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
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.
EAU23101
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
sheath may interfere with proper ca-
ble operation and will cause the in-
ner cable to rust. Replace a
damaged cable as soon as possible
to prevent unsafe conditions.
[EWA10721]
Recommended lubricant:
Engine oil
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