warning YAMAHA XT1200Z 2014 Service Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
6
EAU34226
BatteryThe battery is located behind cowling
A. (See page 6-8.)
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electro-
lyte or to add distilled water. However,
the battery lead connections need to
be checked and, if necessary, tight-
ened.
WARNING
EWA10761
Electrolyte is poisonous an d
d an gerous since it contains sul-
furic aci d, which causes severe b
urns. Avoi d any contact with
skin, eyes or clothin g an d al-
ways shiel d your eyes when
workin g near b atteries. In case
of contact, a dminister the fol-
lowin g FIRST AID.
EXTERNAL: Flush with plenty of water.
INTERNAL: Drink lar ge quan-
tities of water or milk and im-
me diately call a physician.
EYES: Flush with water for 15 minutes an d seek prompt
me dical attention.
 Batteries pro duce explosive hy-
d ro gen gas. Therefore, keep
sparks, flames, ci garettes, etc.,
away from the battery an d pro-
vi de sufficient ventilation when
char gin g it in an enclose d
space.
 KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To char ge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the battery tends to discharge more quick-
ly if the vehicle is equipped with op-
tional electrical accessories.
NOTICE
ECA16522
To char
ge a VRLA (Valve Re gulate d
Lea d Aci d) battery, a special (con-
stant-volta ge) battery char ger is re-
quire d. Usin g a conventional b attery
char ger will damag e the b attery.To store the battery
1. If the vehicle will not be used for more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
NOTICE: When removin g the
b attery, be sure the key is
turne d to “OFF”, then d iscon-
nect the neg ative lead b efore
d isconnectin g the positive lea d.
[ECA16303]
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before in- stallation. NOTICE: When install-
in g the b attery, be sure the key
1. Positive battery lead (red)
2. Negative battery lead (black)
3. Battery1
3
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-30
6
is turne
d to “OFF”, then connect
the positive lea d before con-
nectin g the ne gative lead .
[ECA16841]
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.NOTICE
ECA16531
Always keep the b attery charged .
Storin g a dischar ged battery can
cause permanent battery damag e.
EAU58960
Replacin g the fusesThe fuse boxes and the ABS motor
fuse are located behind cowling A, and
the main fuse, the cruise control fuse
and the brake light fuse are located be-
hind cowling B. (See page 6-8.)
If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and turn off the electrical circuit in question.
2. Remove the blown fuse, and then install a new fuse of the specified
amperage. WARNING! Do not1. ABS motor fuse
2. ABS motor spare fuse
3. Main fuse
4. Spare fuse
5. Cruise control fuse
6. Brake light fuse
7. Fuse box123
5
4
67
1. Headlight fuse
2. ABS solenoid fuse
3. Electronic throttle valve fuse
4. Fuel injection system fuse
5. Backup fuse (for clock and immobilizer sys-
tem)
6. Radiator fan fuse
7. Ignition fuse
8. Signaling system fuse
9. ABS control unit fuse
10.Auxiliary DC jack fuse
11.Parking lighting fuse
12.O/P (option) fuse
13.Spare fuse
13456
2
7
8
9
10
13
11
12
13
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
6
8. Insert a new bulb into the socket.
9. Install the socket (together with
the bulb) by pushing it in and turn-
ing it clockwise.
10. Install the headlight unit by install- ing the bolts, and then tightening
them to the specified torque.
11. Install the headlight unit cover by installing the bolts.
12. Install the panel by installing the screws and the quick fastener
screw.
13. Install the cover. 14. Install the windshield by installing
the screws, and then tightening
them to the specified torque.
WARNING! A loose win dshiel d
coul d cause an acci dent. Be
sure to tig hten the screws to the
specifie d torque.
[EWA15511] EAU24351
Supportin
g the motorcycleSince this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy- cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
1. Auxiliary light bulbTi ghtenin g torque:
Headlight unit bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1
Tightenin g torque:
Windshield screw: 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-37
6a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU25872
Trou
bleshootin gAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checkin g the fuel system, do
not smoke, an d make sure there are
no open flames or sparks in the ar-
ea, inclu din g pilot lig hts from water heaters or furnaces. Gasoline or
g
asoline vapors can i gnite or ex-
plod e, causin g severe injury or prop-
erty damag e.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
6En
gine overheatin g
WARNING
EWAT1041
Do not remove the ra diator cap when the en gine an d ra diator are hot. Scal din g hot flui d an d steam may be
b lown out un der pressure, which coul d cause serious injury. Be sure to wait until the en gine has coole d.
 Place a thick ra g, like a towel, over the ra diator cap, an d then slowly rotate the cap counterclockwise to the
d etent to allow any resi dual pressure to escape. When the hissin g soun d has stoppe d, press d own on the cap
while turnin g it counterclockwise, an d then remove the cap.TIPIf coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended cool-
ant as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
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MOTORCYCLE CARE AND STORAGE7-3
7
windshield. Before using them, make a
test by polishing an area which does
not affect your visibility.
After cleanin
g
1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean- er to remove any remaining dirt.
5. Touch up minor paint damage caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely before storing or covering it.
WARNING
EWA11132
Contaminants on the b rakes or tires
can cause loss of control.  Make sure that there is no oil or
wax on the brakes or tires.
 If necessary, clean the b rake
d iscs an d b rake linin gs with a
re gular brake disc cleaner or
acetone, an d wash the tires with
warm water an d a mil d d eter-
g ent. Before rid ing at hi gher
spee ds, test the motorcycle’s
b rakin g performance an d cor-
nerin g b ehavior.NOTICE
ECA10801
 Apply spray oil an d wax spar-
in gly an d make sure to wipe off
any excess.
 Never apply oil or wax to any
rubber an d plastic parts, b ut
treat them with a suita ble care
prod uct.
 Avoi d using abrasive polishin g
compoun ds as they will wear
away the paint.
TIP Consult a Yamaha dealer for ad-
vice on what products to use.
 Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
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MOTORCYCLE CARE AND STORAGE
7-4
7
EAU49592
StorageShort-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the mo-
torcycle.NOTICE
ECA10811
 Storin g the motorcycle in a
poorly ventilate d room or cover-
in g it with a tarp, while it is still
wet, will allow water an d humi d-
ity to seep in an d cause rust.
 To prevent corrosion, avoi d
d amp cellars, sta bles ( because
of the presence of ammonia)
an d areas where stron g chemi-
cals are stored .Long-term
Before storing your motorcycle for sev-
eral months: 1. Follow all the instructions in the “Care” section of this chapter. 2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to protect the cylinders, piston rings,
etc. from corrosion.a. Remove the spark plug caps and spark plugs.
b. Pour a teaspoonful of engine oil into each spark plug bore.
c. Install the spark plug caps onto the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
d. Turn the engine over several times with the starter. (This will
coat the cylinder walls with oil.)
WARNING! To prevent d am-
a g e or injury from sparkin g,
make sure to groun d the
spark plu g electro des while
turnin g the en gine over.
[EWA10952]
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
4. Lubricate all control cables and the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-29.
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SPECIFICATIONS
8-3
8
Electrical system:Ignition system:TCI
Charging system:
AC magnetoBattery:Model:YTZ12S
Voltage, capacity:
12 V, 11.0 AhHeadlight:Bulb type:Halogen bulbBulb voltage, wattage × quantity:Headlight:
12 V, 55.0 W × 2
Tail/brake light: LED
Front turn signal light:
LED
Rear turn signal light: LED
Auxiliary light: 12 V, 5.0 W × 2
License plate light:
12 V, 5.0 W × 1
Meter lighting: LED
Neutral indicator light: LED
High beam indicator light:
LED
Oil level warning light: LED Turn signal indicator light:
LED
Engine trouble warning light: LED
ABS warning light:
LED
Cruise control “SET” indicator light: LED
Cruise control “ON” indicator light: LED
Immobilizer system indicator light:
LED
Traction control system indicator/warning
light:
LED
Fuses:Main fuse:50.0 A
Headlight fuse:
20.0 A
Brake light fuse: 1.0 A
Signaling system fuse: 7.5 A
Ignition fuse:
20.0 A
Parking lighting fuse: 7.5 A
Radiator fan fuse: 20.0 A
Fuel injection system fuse:
20.0 A
ABS control unit fuse: 7.5 A ABS motor fuse:
30.0 A
ABS solenoid fuse: 20.0 A
Cruise control fuse:
1.0 A
Auxiliary DC jack fuse: 3.0 A
Backup fuse: 7.5 A
Electronic throttle valve fuse:
7.5 A
O/P (option) fuse: 20.0 A
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10-1
10
INDEXAABS ....................................................... 3-26
ABS warning light ................................... 3-5
Air filter element .................................... 6-17
Auxiliary DC jack ................................... 3-42
Auxiliary light bulb, replacing ................ 6-34BBattery .................................................. 6-29
Brake and clutch fluids, changing ........ 6-24
Brake and clutch levers, checking and lubricating ........................................... 6-26
Brake and shift pedals, checking and
lubricating ........................................... 6-25
Brake fluid level, checking .................... 6-23
Brake lever ............................................ 3-25
Brake lever free play, checking............. 6-21
Brake light switches.............................. 6-22
Brake pedal........................................... 3-26CCare ........................................................ 7-1
Carriers ................................................. 3-39
Catalytic converter ................................ 3-31
Clutch lever ................................. 3-24, 6-21
Coolant ................................................. 6-15
Cowlings, removing and installing .......... 6-8
Cruise control indicator lights ................. 3-4
Cruise control switches ........................ 3-23
Cruise control system ............................. 3-6DDimmer/Pass switch ............................. 3-23
D-mode (drive mode) ............................ 3-22EEngine break-in....................................... 5-3
Engine idling speed, checking .............. 6-17 Engine oil and oil filter
cartridge ........... 6-11
Engine trouble warning light ................... 3-5
FFinal gear oil ......................................... 6-14
Front and rear brake pads, checking ... 6-22
Front fork, adjusting ............................. 3-35
Front fork, checking ............................. 6-27
Fuel ....................................................... 3-30
Fuel consumption, tips for reducing ...... 5-3
Fuel tank breather hose and overflow
hose ................................................... 3-31
Fuel tank cap ........................................ 3-29
Fuses, replacing ................................... 6-30HHandlebar switches .............................. 3-22
Hazard switch....................................... 3-23
Headlight bulb, replacing ..................... 6-32
High beam indicator light ....................... 3-4
Horn switch .......................................... 3-23IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ............... 3-40
Immobilizer system ................................ 3-1
Immobilizer system indicator light .......... 3-6
Indicator lights and warning lights ......... 3-4LLicense plate light bulb, replacing........ 6-33
Luggage strap holders ......................... 3-39MMain switch/steering lock....................... 3-2
Maintenance and lubrication, periodic ... 6-4
Maintenance, emission control system.................................................. 6-3
Matte color, caution ............................... 7-1 Menu switch..........................................3-23
Model label .............................................9-1
Multi-function meter unit .......................3-10
NNeutral indicator light ..............................3-4OOil level warning light ..............................3-4PParking ....................................................5-4
Part locations ..........................................2-1RRider seat ..............................................3-32
Rider seat height, adjusting ..................3-33SSafety information ...................................1-1
Select switch.........................................3-24
Shifting ....................................................5-2
Shift pedal .............................................3-25
Shock absorber assembly, adjusting ....3-37
Sidestand ..............................................3-40
Sidestand, checking and lubricating.....6-26
Spark plugs, checking ..........................6-10
Specifications .........................................8-1
Start/Engine stop switch .......................3-23
Starting the engine ..................................5-1
Steering, checking ................................6-28
Storage ...................................................7-4
Supporting the motorcycle ...................6-36
Swingarm pivots, lubricating ................6-27TThrottle grip and cable, checking and
lubricating ...........................................6-25
Throttle grip free play, checking ...........6-17
Tires ......................................................6-18
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INDEX
10-2
10
Tool kit .................................................... 6-2
Traction control system ........................ 3-27
Traction control system indicator/warning light ......................................... 3-5
Troubleshooting.................................... 6-37
Troubleshooting charts......................... 6-38
Turn signal indicator lights ..................... 3-4
Turn signal light and tail/brake light ..... 6-33
Turn signal switch................................. 3-23VValve clearance .................................... 6-18
Vehicle identification number ................. 9-1WWheel bearings, checking .................... 6-28
Wheels .................................................. 6-21
Windshield ............................................ 3-34
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