clutch YAMAHA XT1200Z 2013 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
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator lights and warning lights ............................................3-4
Multi-function meter unit .................3-8
D-mode (drive mode) ....................3-15
Handlebar switches ......................3-16
Clutch lever ...................................3-18
Shift pedal .....................................3-18
Brake lever ...................................3-19
Brake pedal ..................................3-20
ABS ..............................................3-20
Traction control system ................3-21
Fuel tank cap ................................3-23
Fuel ...............................................3-23
Fuel tank breather hose and 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 ............................... 6-2
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 ........................................... 6-21
Brake light switches ..................... 6-21
Checking the front and rear brake
pads .......................................... 6-22
Checking the brake fluid level ...... 6-22
Changing the brake and clutch
fluids ......................................... 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 ....... 6-26
Lubricating the swingarm pivots ........................................ 6-26
Checking the front fork ................. 6-27
Checking the steering .................. 6-27U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments
8
7654
321
9
10
1. Clutch lever (page 3-18)
2. Left handlebar switches (page 3-16)
3. Clutch fluid reservoir (page 6-24)
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 3-19) 9. Throttle grip (page 6-17)
10.Main switch/steering lock (page 3-2)
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
EAU12830
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch lever position adjusting dial. To
adjust the distance between the clutch
lever and the handlebar grip, turn the
adjusting dial while holding the lever
pushed away from the handlebar grip.Make sure that the appropriate setting
on the adjusting dial is aligned with the
arrow mark on the clutch lever.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-33.)
EAU12871
Shift pedal The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
1. Clutch lever
2. Clutch lever position adjusting dial
3. Arrow mark
4. Distance between clutch lever and handlebar
grip
12
34
1
4
3
2
1. Shift pedal
1
U23PE3E0.book Page 18 Monday, July 30, 2012 8:44 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-33
3this system regularly and have a
Yamaha dealer repair it if it does not function properly.
EAU44902
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.●
It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.
●
It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
●
It cuts the running engine when the
transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
U23PE3E0.book Page 33 Monday, July 30, 2012 8:44 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-34
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
YES NO YES NO YES NO
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The sidestand switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.• The vehicle must be placed on the center-
stand during this inspection.• If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
U23PE3E0.book Page 34 Monday, July 30, 2012 8:44 AM

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. 6-22, 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
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.
—
Sidestand switch Check operation of ignition circuit cut-off system.
If system is not working correctly, have Yamaha dealer check vehicle. 3-32
ITEM CHECKS PAGE
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU48710
TIPThis model is equipped with:●
a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the multi-function display in-
dicates error code 30, but this is
not a malfunction. Turn the key to
“OFF” and then to “ON” to clear the
error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.
●
an engine auto-stop system. The
engine stops automatically if left
idling for 20 minutes. If the engine
stops, simply push the start switch
to restart the engine.
EAU54520
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:●
The transmission is in the neutral
position.
●
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
See page 3-33 for more informa-
tion.
1. Turn the key to “ON” and make sure that the engine stop switch is
set to “ ”.
The following warning lights and
indicator lights should come on for
a few seconds, then go off.●
Oil level warning light
●
Engine trouble warning light
●
Coolant temperature warning
light
●
Traction control system indi-
cator/warning light
●
Immobilizer system indicator
light
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
NOTICE
ECA10260
●
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
●
Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16810
Tips for reducing fuel con-
sumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:●
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
●
Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
●
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17123
0–1000 km (0–600 mi)
Avoid prolonged operation above 3900
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil and
final gear oil must be changed, and
the oil filter cartridge or element re-
placed.
[ECA10332]
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770F
General maintenance and lubrication chart 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)
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 *Brake fluid Replace. Every 2 years
7 *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.
8 *Tires Check tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary. √√√√√
9 *Wheel bearings Check bearing for looseness or
damage. √√√√
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
10*Swingarm Check operation and for exces-
sive play. √√√√
Lubricate with lithium-soap-based grease. Every 50000 km (30000 mi)
11 *Steering bearings Check bearing play and steering
for roughness. √√√√√
Lubricate with lithium-soap-based grease. Every 50000 km (30000 mi)
12 *Chassis fasteners Make sure that all nuts, bolts and
screws are properly tightened. √√√√√
13 Brake lever pivot
shaft Lubricate with silicone grease.
√√√√√
14 Brake pedal pivot
shaft Lubricate with lithium-soap-based
grease. √√√√√
15 Clutch lever pivot
shaft
Lubricate with silicone grease.
√√√√√
16 Shift pedal pivot
shaft Lubricate with lithium-soap-based
grease. √√√√√
17 Sidestand, center-
stand Check operation.
Lubricate with lithium-soap-based
grease. √√√√√
18 *Sidestand switch Check operation. √√√√√√
19 *Front fork Check operation and for oil leak-
age. √√√√
20 *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)
U23PE3E0.book Page 5 Monday, July 30, 2012 8:44 AM