YAMAHA XT1200Z 2019 Repair Manual

Operation and important ri din g points
5-4
5
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 both brakes an d apply
them smoothly.
 Make sure that the motorcycle
and the eng ine 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 d rive train dam-
a g e.
EAU16811
Tips for re ducin g fuel con-
sumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
 Shift up swiftly, and avoid high en-
gine speeds during acceleration.
 Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
 Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
UBP8E1E0.book Page 4 Friday, September 14, 2018 11:35 AM

Operation and important rid ing points
5-5
5
EAU16842
En gine 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 fol-
lowing 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.
EAU58991
0–1000 km (0–600 mi)
Avoid prolonged operation above 3900
r/min. NOTICE: After 1000 km (600
mi) of operation, the en gine oil an d
final gear oil must be chan ged , an d
the oil filter cartri dge or element re-
place d.
[ECA10333]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 4700
r/min.
1600 km (1000 mi) an d b eyon d
The vehicle can now be operated nor-
mally.
NOTICE
ECA23060
 Keep the en gine spee d out of
the tachometer hi gh-r/min
zone. 
If any en gine trou ble shoul d oc-
cur durin g the en gine break-in
perio d, imme diately have a
Yamaha dealer check the vehi-
cle.
UBP8E1E0.book Page 5 Friday, September 14, 2018 11:35 AM

Operation and important ri din g points
5-6
5
EAU17214
Parkin g
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10312
Since the en gine an d exhaust
system can become very hot,
park in a place where ped estri-
ans or chil dren are not likely to
touch them and b e burne d.
 Do not park on a slope or on soft
groun d, otherwise the vehicle
may overturn, increasin g the
risk of a fuel leak an d fire.
 Do not park near g rass or other
flammab le materials which
mi ght catch fire.
UBP8E1E0.book Page 6 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-1
6
EAU17246
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 performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or d eath durin g
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 body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine 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 1-3 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
touchin g them.
UBP8E1E0.book Page 1 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-2
6
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.
EAU85230
Tool kit
The tool kit is in the location shown.
The information included in this manual
and the tools provided in the tool kit are
intended to assist you in the perfor-
mance of preventive maintenance and
minor repairs. However, a torque
wrench and other tools are necessary
to perform certain maintenance work
correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
your Yamaha dealer perform it for you.
1. Tool kit
1. Hexagon wrench
1
1
UBP8E1E0.book Page 2 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-3
6
EAU71033
Perio dic maintenance charts
TIP
 Items marked with an asterisk should be performed by your Yamaha dealer
because these items require special tools, data, and technical skills.
 From 50000 km (30000 mi), repeat the maintenance intervals starting from
10000 km (6000 mi).
 The annual checks must be performe d every year, except if a d istance-
b ase d maintenance is performe d instea d.
EAU71071
Perio dic maintenance chart for the emission control system
NO. ITEM
1 *Fuel line • Check fuel hoses for cracks or
damage.
• Replace if necessary. √√√√√
2 *Spark plu gs • Check condition.
• Adjust gap and clean.
√√
• Replace. √√
3 *Valve clearance • Check and adjust. Every 40000 km (24000 mi)
4 *Fuel injection • Check engine idle speed.
√√√√√√
• Check and adjust synchroniza- tion. √√√√√
5 *Exhaust system • Check for leakage.
• Tighten if necessary.
• Replace gaskets if necessary. √√√√√
6 *Evaporative emis-
sion control sys-
tem • Check control system for dam-
age.
• Replace if necessary. √√X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi ODOMETER
READINGS
ANNUAL CHECK
1 10203040
0.6 6 12 18 24
UBP8E1E0.book Page 3 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-4
6
EAU71372
General maintenance an d lu brication chart
NO. ITEM
1 *Dia
gnostic system
check • Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes. √√√√√√
2 *Air filter element • Replace. Every 40000 km (24000 mi)
3 *Clutch • Check operation, fluid level and
vehicle for fluid leakage. √√√√√
4 *Front brake • Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces- sary. √√√√√√
5 *Rear brake • Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces- sary. √√√√√√
6 *Brake hoses • Check for cracks or damage.
√√√√√
• Replace. Every 4 years
7 *Brake flui d • Change. Every 2 years
8 *Wheels • Check runout and for damage.
• Tighten all spokes. At the initial interval and every
5000 km (3000 mi) thereafter
9 *Tires • Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√√√√
10 *Wheel bearin gs • Check bearing for looseness or
damage. √√√√
11 *Swin
garm pivot
b earin gs • Check operation and for exces-
sive play. √√√√
• Lubricate with lithium-soap- based grease. Every 50000 km (30000 mi)
12 *Steerin g b earin gs • Check bearing assemblies for
looseness. √√√√√
•

Moderately repack with lithium-
soap-based grease. Every 50000 km (30000 mi)
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
UBP8E1E0.book Page 4 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-5
6
13 *Chassis fasteners • Make sure that all nuts, bolts
and screws are properly tight-
ened. √√√√√
14 Brake lever pivot
shaft
• Lubricate with silicone grease.
√√√√√
15 Brake pe
dal pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
16 Clutch lever pivot
shaft • Lubricate with silicone grease.
√√√√√
17 Shift pe
dal pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
18 Si destan d • Check operation.
• Lubricate with lithium-soap-
based grease. √√√√√
19 *Sidestan d switch • Check operation and replace if
necessary. √√√√√√
20 *Front fork • Check operation and for oil
leakage.
• Replace if necessary. √√√√
21 *Shock ab
sorber
assem bly • Check operation and for oil
leakage.
• Replace if necessary. √√√√
22 *Rear suspension
relay arm an
d con-
nectin g arm pivot-
in g points • Check operation.
√√√√
23 En gine oil • Change (warm engine before
draining).
• Check oil level and vehicle for oil leakage. √√√√√√
24 En
gine oil filter
cartri dge • Replace.
√√√
25 *Co

olin g system • Check coolant level and vehicle
for coolant leakage. √√√√√
• Change. Every 3 years
NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi ODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
UBP8E1E0.book Page 5 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-6
6
EAU72841
TIP
Air filter
 This model’s air filter uses a disposable oil-coated paper element, which
must be replaced. Do not clean with compressed air, doing so will only dam-
age it.
 The air filter element needs to be replaced more frequently if you often ride in
the rain or dusty areas.
Hydraulic brake and clutch service  Regularly check the brake fluid and clutch fluid reservoirs. Replenish as nec-
essary.
 Every two years replace the internal components of the brake master cylin-
ders 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 or sooner if cracked or
damaged.
26 *Final gear oil • Check oil level and vehicle for
oil leakage. √√√√√
• Change. √√√
27 *Front an
d rear
b rake switches • Check operation.
√√√√√√
28 *Movin
g parts an d
cab les • Lubricate.
√√√√√
29 *Throttle
grip hous-
in g an d cab le • Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous- ing and cable. √√√√√
30 *Li
ghts, si gnals an d
switches • Check operation.
• Adjust headlight beam.
√√√√√√
NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
UBP8E1E0.book Page 6 Friday, September 14, 2018 11:35 AM

Periodic maintenance an d a djustment
6-7
6
EAU18782
Removin g an d installin g cowl-
in gs
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.
EAU55960
Cowlin g A
To remove the cowling
Remove 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.
Cowlin g B
To remove the cowling
1. 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. Cowling C
1
2
1
1. Cowling A
2. Quick fastener screw
1. Projection
2. Matching hole
3. Cowling B
2
2
1
123
UBP8E1E0.book Page 7 Friday, September 14, 2018 11:35 AM