clutch YAMAHA XT1200Z 2015 User Guide

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
6-4
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
6-13
6
TIPMake sure that the O-ring is properly
seated.10. Install the new oil filter cartridgewith an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench. 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
ECA11621
In or der to prevent clutch slip-
pa ge (since the en gine oil also
lu bricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a hi gh-
er quality than specifie d. In
1. O-ring
1. Torque wrench
Ti ghtenin g torque:
Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)
Ti ghtenin g 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
Recommen ded en gine 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
6-21
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
6-24
6fluid level goes down suddenly, have a
Yamaha dealer check the cause before further riding.
EAU22754
Chan gin g the brake an d
clutch flui dsHave a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the brake and clutch
master cylinders and calipers as well
as the brake and clutch hoses replaced
at the intervals listed below or whenev-
er they are damaged or leaking.
 Oil seals: Replace every two
years.
 Brake and clutch hoses: Replace
every four years.
EAU23115
Checkin g an d lu bricatin g the
throttle grip an d ca bleThe operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from wa-
ter entry. Therefore, use care not to
pour water directly onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6
EAU44275
Checking an d lu bricatin g the
b rake an d shift pe dalsThe operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Brake pe dal
Shift pe dal
EAU43602
Checkin g an d lu bricatin g the
b rake an d clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever
Clutch lever
Recommen ded lu bricant:
Lithium-soap-based grease
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SPECIFICATIONS
8-1
8
Dimensions:Overall length:2250 mm (88.6 in)
Overall width:
980 mm (38.6 in)
Overall height: 1410/1470 mm (55.5/57.9 in)
Seat height: 845/870 mm (33.3/34.3 in)
Wheelbase:
1540 mm (60.6 in)
Ground clearance: 190 mm (7.48 in)
Minimum turning radius: 2700 mm (106.3 in)Wei ght:Curb weight:
257 kg (567 lb)Engine:Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement: Inline 2-cylinder
Displacement: 1199 cm³
Bore × stroke:
98.0 × 79.5 mm (3.86 × 3.13 in)
Compression ratio: 11.0 : 1
Starting system: Electric starter
Lubrication system:
Dry sump
Engine oil:Recommended brand:
YAMALUBE
Type:
SAE 10W-40, 10W-50, 15W-40, 20W-40 or
20W-50
Recommended engine oil grade: API service SG type or higher, JASO
standard MA
Engine oil quantity:
Without oil filter cartridge replacement: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)Final gear oil:Type:
Yamaha genuine shaft drive gear oil SAE 80W-90 API GL-5 or SAE 80 API GL-4
Hypoid gear oil
Quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt)
Coolant quantity:Coolant reservoir (up to the maximum level
mark):0.26 L (0.27 US qt, 0.23 Imp.qt)
Radiator (including all routes): 1.83 L (1.93 US qt, 1.61 Imp.qt)Air filter:Air filter element:Oil-coated paper elementFuel:Recommended fuel:
Premium unleaded gasoline (Gasohol (E10)
acceptable)
Fuel tank capacity:
23.0 L (6.08 US gal, 5.06 Imp.gal)
Fuel reserve amount: 3.9 L (1.03 US gal, 0.86 Imp.gal)Fuel injection:Throttle body:
ID mark:2BS1 00Spark plu g(s):Manufacturer/model:
NGK/CPR8EB9
Spark plug gap: 0.8–0.9 mm (0.031–0.035 in)Clutch:Clutch type:Wet, multiple-discTransmission:Primary reduction ratio:
1.466 (85/58)
Final drive: Shaft
–20 –10 0 1020 30 40 50 C
10 30 50 70 90 110
0 130 F
SAE 20W-50SAE 20W-40SAE 15W-40SAE 10W-40SAE 10W-50
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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 ................ 6-33BBattery .................................................. 6-28
Brake and clutch fluids, changing ........ 6-24
Brake and clutch levers, checking and lubricating ........................................... 6-25
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....................................... 5-4
Engine idling speed, checking .............. 6-17 Engine oil and oil filter
cartridge ........... 6-11
Engine serial number .............................. 9-1
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 ...... 5-4
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 ..................... 6-31
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........ 6-35
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 ....................................................5-5
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 ................................6-27
Storage ...................................................7-4
Supporting the motorcycle ...................6-36
Swingarm pivots, lubricating ................6-26TThrottle grip and cable, checking and
lubricating ...........................................6-24
Throttle grip free play, checking ...........6-17
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