oil YAMAHA XT1200Z 2011 User Guide

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
6-10
6
EAU19652
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4
–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.NOTICE
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in.
Specified spark plug: NGK/CPR8EB9
1. Spark plug gapSpark plug gap:0.8 –0.9 mm (0.031 –0.035 in)
Tightening torque: Spark plug:13 Nm (1.3 m ·kgf, 9.4 ft· lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
EAU49503
Engine oil and oil filter car-
tridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level1. Place the vehicle on the center- stand. A slight tilt to the side can
result in a false reading.
2. Start the engine and warm it up for ten minutes until the engine oil has
reached a normal temperature of
60 °C (140 ° F), and then turn the
engine off.
3. Wait a few minutes until the oil set- tles, and then check the oil level
through the engine oil level check
window located at the bottom-right
side of the crankcase.TIPThe engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter cartridge replace-
ment) 1. Place the vehicle on a level sur- face.
2. Start the engine, warm it up for several minutes, and then turn it
off.
3. Place an oil pan under the oil tank to collect the used oil. 4. Remove the engine oil filler cap,
the drain bolt and its gasket to
drain the oil from the oil tank.
5. Place an oil pan under the engine to collect the used oil.
6. Remove the engine oil drain bolt and its gasket to drain the oil from
the crankcase.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
42
3
1
1. Engine oil drain bolt (oil tank)
2. Gasket
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPSkip steps 7–11 if the oil filter cartridge
is not being replaced.7. Remove cowling C. (See page 6-8.)
8. Remove the oil filter cartridge with an oil filter wrench.
TIPAn oil filter wrench is available at a
Yamaha dealer.9. Apply a thin coat of clean engine oil to the O-ring of the new oil filter
cartridge.
TIPMake sure that the O-ring is properly
seated.10. Install the new oil filter cartridge with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
1. Engine oil drain bolt (crankcase)
2. Gasket
12
1. Engine oil filter cartridge
2. Oil filter wrench21
1. O-ring
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
11. Install the cowling.
12. Install the engine oil drain bolts
and their new gasket, and then
tighten the bolts to the specified
torques. 13. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “ CD” or oils of a high-
er quality than specified. In addition, do not use oils labeled
“
ENERGY CONSERVING II ” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
14. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.TIPAfter the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.NOTICE
ECA10401
If the oil level warning light flickers
or remains on even if the oil level is
correct, immediately turn the engine
off and have a Yamaha dealer check
the vehicle.15. Turn the engine off, wait a few min-utes until the oil settles, and then
check the oil level and correct it if
necessary.
1. Torque wrenchTightening torque:Oil filter cartridge:17 Nm (1.7 m ·kgf, 12 ft ·lbf)
Tightening torques: Engine oil drain bolt (crankcase):
20 Nm (2.0 m ·kgf, 14 ft ·lbf)
Engine oil drain bolt (oil tank): 20 Nm (2.0 m ·kgf, 14 ft ·lbf)1
Recommended engine oil:
See page 8-1.
Oil quantity: Without oil filter cartridge replace-
ment:3.10 L (3.28 US qt, 2.73 Imp.qt)
With oil filter cartridge replacement:
3.40 L (3.59 US qt, 2.99 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
EAU20016
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the vehicle. In addi-
tion, the final gear oil level must be
checked and the oil changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
WARNING
EWA10370


Make sure that no foreign mate-
rial enters the final gear case.


Make sure that no oil gets on the
tire or wheel.
To check the final gear oil level1. Place the vehicle on the center- stand.TIPMake sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.2. Remove the final gear oil filler boltand its gasket, and then check the
oil level in the final gear case.
TIPThe oil level should be at the brim of the
filler hole.3. If the oil is below the brim of the fill-er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
4. Check the gasket for damage, and replace it if necessary.
5. Install the final gear oil filler bolt and its gasket, and then tighten the
bolt to the specified torque. To change the final gear oil
1. Place the vehicle on a level sur- face.
2. Place an oil pan under the final gear case to collect the used oil.
3. Remove the final gear oil filler bolt, the final gear oil drain bolt and their
gasket to drain the oil from the final
gear case.
4. Install the final gear oil drain bolt and its new gasket, and then tight-
en the bolt to the specified torque.1. Final gear oil filler bolt
2. Gasket
3. Correct oil level
1
2
3
Tightening torque: Final gear oil filler bolt:
23 Nm (2.3 m ·kgf, 17 ft· lbf)1. Final gear oil filler bolt
2. Final gear oil drain bolt
3. Gasket
231
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
5. Refill with the recommended final
gear oil to the brim of the filler hole.
6. Check the oil filler bolt gasket for damage, and replace it if neces-
sary.
7. Install the oil filler bolt and its gas- ket, and then tighten the bolt to the
specified torque.
8. Check the final gear case for oil leakage. If oil is leaking, check for
the cause.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU40154
To check the coolant level1. Place the vehicle on the center- stand.TIP

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-ant reservoir.TIPThe coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below theminimum level mark, remove the
coolant reservoir cap.
Tightening torque:Final gear oil drain bolt:
23 Nm (2.3 m ·kgf, 17 ft ·lbf)
Recommended final gear oil: Yamaha genuine shaft drive gear oil
SAE 80 API GL-5 or SAE 80 API
GL-4 Hypoid gear oil
Oil quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt)
Tightening torque: Final gear oil filler bolt:
23 Nm (2.3 m ·kgf, 17 ft ·lbf)
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir cap
2
1
31
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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.
EAU23095
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
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711]
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6
EAUM1651
Lubricating the swingarm piv-
ots The swingarm pivots must be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23272
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
Recommended lubricant:Lithium-soap-based grease
Recommended lubricant:Lithium-soap-based grease
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