maintenance YAMAHA XT1200Z 2010 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/overflow hose ..........................................3-24
Catalytic converter ........................3-25
Rider seat .....................................3-25
Adjusting the rider seat height ......3-26
Windshield ....................................3-28 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 ............................... 6-1
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 cable 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 ....................................... 6-23
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 ....... 6-25U23PE0E0.book Page 1 Wednesday, March 3, 2010 2:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-24
3ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU49460
NOTICE
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.Your Yamaha engine has been de-
signed to use premium unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand. Use of unleaded fuel will extend
spark plug life and reduce maintenance
costs.
EAU34072
Fuel tank breather/overflow
hose Before operating the motorcycle:

Check the fuel tank breather/over-
flow hose connection.


Check the fuel tank breather/over-
flow hose for cracks or damage,
and replace it if damaged.


Make sure that the end of the fuel
tank breather/overflow hose is not
blocked, and clean it if necessary.


Make sure that the end of the fuel
tank breather/overflow hose is po-
sitioned outside of the cowling.
Recommended fuel:
PREMIUM UNLEADED GASOLINE
ONLY
Fuel tank capacity:
23.0 L (6.08 US gal, 5.06 Imp.gal)
Fuel reserve amount: 3.9 L (1.03 US gal, 0.86 Imp.gal)
1. Fuel tank breather/overflow hose
1
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INSTRUMENT AND CONTROL FUNCTIONS
3-25
3
EAU13433
Catalytic converter This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:

Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.


Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.


Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.


Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
EAU49442
Rider seat To remove the rider seat1. Insert the key into the rider seat lock, and then turn it counterclock-
wise.
2. Lift the front of the rider seat and push the seat forward.
To install the rider seat 1. Insert the projection on the rear of the rider seat into the seat holder
as shown, and then push the front
of the seat down to lock it in place.1. Unlock.
2. Rider seat lock
2
1
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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 the fuel tank breather/overflow hose for obstructions, cracks or damage,
and check the hose connection. 3-23, 3-24
Engine oil 
Check oil level in oil tank.
 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 recommended brake fluid to specified level.
 Check hydraulic system for leakage. 6-21, 6-22
U23PE0E0.book Page 1 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.


Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU49561
Owner’ s tool kit The owner ’s tool kit is located behind
cowling A. (See page 6-8.)
To access the owner's tool kit, remove
cowling A with the hexagon wrench, lo-
cated on the bottom of the rider seat.
(See page 3-25.)1. Owner ’s tool kit
1. Hexagon wrench
1
1
U23PE0E0.book Page 1 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6The service information included in this
manual and the tools provided in the
owner
’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.U23PE0E0.book Page 2 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU46861
TIP

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.


From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
EAU46910
Periodic maintenance chart for the emission control system 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 *Fuel line 
Check fuel hoses for cracks or
damage. √√√√√
2 *Spark plugs 
Check condition.
 Clean and regap. √√
 Replace. √√
3 *Valves 
Check valve clearance.
 Adjust. Every 40000 km (24000 mi)
4 *Fuel injection sys-
tem 
Adjust synchronization. √√√√√
5 *Muffler and exhaust
pipe 
Check the screw clamp(s) for
looseness. √√√√√
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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)
U23PE0E0.book Page 5 Wednesday, March 3, 2010 2:29 PM

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