brake YAMAHA XT1200Z 2015 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
3-27
3
TIPThe ABS performs a self-diagno-
sis test each time the vehicle first
starts off after the key is turned to
“ON” and the vehicle has traveled
at a speed of 10 km/h (6 mi/h) or
higher. During this test, a “click-
ing” noise can be heard from un-
der the seat, and if the brake lever
or brake pedal is even slightly ap-
plied, a vibration can be felt at the
lever and pedal, but these do not
indicate a malfunction.
 This ABS has a test mode which
allows the owner to experience
the pulsation at the brake lever or
brake pedal when the ABS is op-
erating. However, special tools are
required, so please consult your
Yamaha dealer.NOTICE
ECA16831
Keep any type of mag nets (includin g
ma gnetic pick-up tools, ma gnetic
screwd rivers, etc.) away from the
front an d rear wheel hu bs; other-
wise, the ma gnetic rotors equippe d
in the wheel hu bs may be damag ed , resultin
g in improper performance
of the ABS an d the unifie d b rake
system.
EAU58952
Traction control systemThe traction control system helps
maintain traction when accelerating on
slippery surfaces, such as unpaved or
wet roads. If sensors detect that the
rear wheel is starting to slip (uncon-
trolled spinning), the traction control
system assists by regulating engine
power as needed until traction is re-
stored. The traction control system in-
dicator/warning light flashes to let the
rider know that traction control has en-
gaged.TIPThe rider may also notice slight chang-
es in engine and exhaust sounds when
the traction control system is engaged.
WARNING
EWA15432
The traction control system is not a
su bstitute for rid ing appropriately
for the con ditions. Traction control
cannot prevent loss of traction due
to excessive speed when entering
turns, when acceleratin g har d at a
sharp lean an gle, or while brakin g,
an d cannot prevent front wheel slip-
1. Front wheel hub
1. Rear wheel hub
11
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15598
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
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an acci dent or equipment damag e.
Do not operate the vehicle if you fin d any pro blem. If a pro blem cannot be corrected b y the proce dures provi ded in
this manual, have the vehicle inspecte d b y 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 fuel tank breather hose and overflow hose for obstructions, cracks or
damage, and check hose connections. 3-30, 3-31
En gine oil • Check oil level in engine.
• 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 specified brake fluid to specified level.
• Check hydraulic system for leakage. 6-22, 6-23
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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, 6-23
Clutch • Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check hydraulic system for leakage. 6-21
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 ca-
ble and grip housing. 6-17, 6-24
Wheels an d tires • Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary. 6-18, 6-20
Brake an d shift pe dals • Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-25
Brake an d clutch levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-25
Si destan d • Make sure that operation is smooth.
• Lubricate pivot if necessary. 6-26
Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, li ghts, si gnals
an d switches • Check operation.
• Correct if necessary.
—
Si destan d switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle. 3-40
ITEM CHECKS PAGE
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OPERATION AND IMPORTANT RIDING POINTS
5-3
5
NOTICE
ECA10261
Even with the transmission in
the neutral position, do not
coast for lon g period s of time
with the en gine off, an d d o not
tow the motorcycle for lon g d is-
tances. The transmission is
properly lu bricated only when
the en gine is runnin g. Ina de-
quate lu brication may damag e
the transmission.
 Always use the clutch while
chan gin g g ears to avoi d d am-
a g in g the en gine, transmission,
an d d rive train, which are not
d esi gne d to withstan d the
shock of force d shifting .
EAU16682
To start out an d accelerate
1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at the same time, release the clutch
lever slowly. 4. At the recommended shift points
shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second gear. (Make sure not to shift the
transmission into the neutral posi-
tion.)
6. Open the throttle part way and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next higher gear.
TIPWhen shifting gears in normal operat-
ing conditions, use the recommended
shift points.
EAU58270
To decelerate
1. Release the throttle and apply both the front and the rear brakes
smoothly to slow the motorcycle.
2. At the recommended shift points shown in the following table, shift
to a lower gear.
3. When the motorcycle reaches 20 km/h (12 mi/h), the engine is about
to stall or runs roughly, pull the clutch lever in, use the brakes to
slow the motorcycle, and continue
to downshift as necessary.
4. Once the motorcycle has stopped, the transmission can be
shifted into the neutral position.
The neutral indicator light should
come on and then the clutch lever
can be released.
WARNING
EWA17380
Improper brakin g can cause
loss of control or traction. Al-
ways use b oth brakes an d apply
them smoothly.
 Make sure that the motorcycle
and the en gine have sufficiently
slowe d b efore shiftin g to a low-
er gear. En gag in g a lower gear
when the vehicle or en gine
speed is too hi gh coul d make
the rear wheel lose traction or
the en gine to over-rev. This
coul d cause loss of control, an
acci dent an d injury. It coul d also
cause en gine or drive train dam-
a g e.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17245
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on b ody
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the eng ine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to
d eath. See pag e 1-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot during
use. To avoi d possi ble burns, let
b rake components cool before
touching them.
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and
equipped to perform these particular
services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770K
General maintenance and lu brication chartNO. 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 flui d • Replace. Every 2 years
7 *Wheels • Check rim runout and spokes for
damage.
• Tighten all spokes. 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 bearin gs • Check bearings for looseness or
damage. √√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
10*Swin garm • Check operation and for exces-
sive play. √√√√
• Lubricate with lithium-soap- based grease. Every 50000 km (30000 mi)
11 *Steerin g b earin gs • 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 ped
al pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
15 Clutch lever pivot
shaft
• Lubricate with silicone grease.
√√√√√
16 Shift pe
dal pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
17 Si destan d • Check operation.
• Lubricate with lithium-soap-
based grease. √√√√√
18 *Sidestan d switch • Check operation. √√√√√√
19 *Front fork • Check operation and for oil leak-
age. √√√√
20 *Shock a
bsor ber as-
sem bly • 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 k
m
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU36773
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
6-21
6
EAU42851
Clutch leverSince this model is equipped with a hy-
draulic clutch, adjusting the clutch le-
ver free play is not needed. However, it
is necessary to check the hydraulic
system for leakage before each ride. If
the clutch lever free play does become
excessive, and shifting becomes rough
or clutch slippage occurs, causing
poor acceleration, there may be air in
the clutch system. If there is air in the
hydraulic system, have a Yamaha deal-
er bleed the system before operating
the motorcycle.
EAU37914
Checking the brake lever free
playThere should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14212
A soft or spon gy feelin g in the brake
lever can in dicate the presence of
air in the hy draulic system. If there is
air in the hy draulic system, have a
Yamaha dealer blee d the system be-
fore operatin g the vehicle. Air in the
hy draulic system will diminish the b
rakin g performance, which may re-
sult in loss of control an d an acci-
d ent.1. No brake lever free play
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6
EAU22283
Brake light switchesThe brake light, which is activated by
the brake pedal and brake lever,
should come on just before braking
takes effect. Since the brake light
switches are components of the cruise
control system, they must be adjusted
by a Yamaha dealer, who has the nec-
essary professional knowledge and ex-
perience.
EAU22393
Checkin g the front an d rear
b rake pa dsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36891
Front brake pa ds
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn to
the point that a wear indicator almost touches the brake disc, have a
Yamaha dealer replace the brake pads as a set.
EAU22501
Rear brake pad s
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.
1. Brake pad wear indicator
1
1
1. Lining thickness
11
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