YAMAHA XT1200Z 2012 Repair Manual

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. √√√√
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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 with ethylene glycol anti-
freeze coolant. 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 
Check operation.
 Check throttle grip free play, and
adjust if necessary.
 Lubricate cable and grip housing. √√√√√
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)
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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
6-8
6
EAU18781
Removing and installing cowl-
ings The cowlings shown need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.
Refer to this section each time a cowl-
ing needs to be removed and installed.
EAU49532
Cowling A
To remove the cowlingRemove the quick fastener screws, and
then pull the cowling off as shown.To install the cowling
1. Fit the projections on the cowling
into the matching holes in cowling
B.
2. Install the quick fastener screws.
EAU49520
Cowling B
To remove the cowling1. Remove cowling A.
2. Remove the bolts and the quick fasteners, and then pull the cowl-
ing off.
1. Cowling A
2. Cowling B
1
2
1. Cowling C
1. Cowling A
2. Quick fastener screw
1
2
2
1
1. Projection
2. Matching hole
3. Cowling B
12
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6To install the cowling
1. Place the cowling in the originalposition, and then install the bolts
and the quick fasteners.
2. Install cowling A.
EAU49550
Cowling C
To remove the cowlingRemove the bolts and the nuts, and
then take the cowling off.
To install the cowling
Place the cowling in the original posi-
tion, and then install the bolts and the
nuts.
1. Cowling B
2. Bolt
1. Quick fastener
2
1
2
1
1. Cowling C
2. Nut
3. Bolt
2
3
1
1. Cowling C
2. Nut
3. Bolt
12
3
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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 gap
Spark 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 engineoil 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. Oil filter cartridge
2. Oil filter wrench21
1. O-ring
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
611. 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)
U23PE2E0.book Page 13 Monday, August 1, 2011 4:25 PM