YAMAHA XT1200Z 2019 Manual PDF

Periodic maintenance an d a djustment
6-8
6
To install the cowling
1. Place the cowling in the original position, and then install the bolts
and the quick fasteners.
2. Install cowling A.
Cowlin g C
To remove the cowling
Remove the bolts and the nuts, and
then take the cowling off. To install the cowling
Place the cowling in the original posi-
tion, and then install the bolts and the
nuts.
1. Cowling B
2. Bolt
1. Quick fastener
21
2
1
1. Cowling C
2. Nut
3. Bolt
1. Cowling C
2. Nut
3. Bolt
2
3
1
1
2
3
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Periodic maintenance an d a djustment
6-9
6
EAU19653
Checkin g the spark plu gs
The spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and depos- its will cause any spark plug to slowly
erode, they should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition of
the engine.
The porcelain insulator around the
center electrode of each spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally), and all spark plugs installed
in the engine should have the same
color. If any spark plug shows a dis-
tinctly different color, the engine could
be operating improperly. Do not at-
tempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the spark
plug threads.
TIP
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4–
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
NOTICE
ECA10841
Do not use any tools to remove or in-
stall the spark plu
g cap, otherwise
the i gnition coil coupler may get
d amag ed . The spark plu g cap may
b e difficult to remove because the
ru bber seal on the en d of the cap fits
ti g htly. To remove the spark plu g
cap, simply twist it b ack and forth
while pullin g it out; to install it, twist
it back an d forth while pushin g it in.
Specifie d spark plu g:
NGK/CPR8EB9
1. Spark plug gap
Spark plu g g ap:
0.8–0.9 mm (0.031–0.035 in)
Ti ghtening torque:
Spark plug: 13 N·m (1.3 kgf·m, 9.6 lb·ft)
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Periodic maintenance an d a djustment
6-10
6
EAU79401
Canister
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this vehicle, make sure to check the
following:
 Check each hose connection.
 Check each hose and canister for
cracks or damage. Replace if
damaged.
 Make sure that the canister
breather hose is not blocked, and
if necessary, clean it.
 Make sure that the canister
breather hose is positioned out-
side of the cowling.
EAU58603
Engine oil
The engine oil level should be checked
regularly. In addition, the oil must be
changed and the oil filter cartridge re-
placed at the intervals specified in the
periodic maintenance chart.
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 specified . In
a dd ition, do not use oils la bele d
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn mate-
rial enters the crankcase.
To check the en gine oil level
1. With the vehicle on a level surface, hold it upright for an accurate
reading.
2. Start the engine and warm it up for ten minutes until the engine oil has
reached a normal temperature of
60 °C (140 °F), and then turn the
engine off.
3. Wait a few minutes for the oil level to settle for an accurate reading,
and then check the oil level
1. Canister
2. Canister breather hose
2
1
Recommen ded en gine oil:
See page 8-1.
Oil quantity: Oil change: 3.10 L (3.28 US qt, 2.73 Imp.qt)
With oil filter removal: 3.40 L (3.59 US qt, 2.99 Imp.qt)
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Periodic maintenance an d a djustment
6-11
6 through the engine oil level check
window located at the bottom-
right side of the crankcase.
TIP
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is at or below the
minimum level mark, remove the
oil filler cap and add oil.
5. Check the engine oil filler cap O- ring. Replace if damaged.
6. Install the engine oil filler cap. To chan
ge the en gine oil (an d filter)
1. Start the engine and allow it to idle for a few minutes to warm up the
oil, and then stop the engine.
2. Place an oil pan under the oil tank to collect the used oil.
3. Remove the engine oil filler cap, the drain bolt and its gasket to
drain the oil from the oil tank.
4. Place an oil pan under the engine to collect the used oil.
5. Remove the engine oil drain bolt and its gasket to drain the oil from
the crankcase.
TIP
Skip steps 6–10 if the oil filter cartridge
is not being replaced.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
1. Engine oil filler cap
2. O-ring
4
2
3
1
2
1
1. Engine oil drain bolt (oil tank)
2. Gasket
1. Engine oil drain bolt (crankcase)
2. Gasket
1
2
1
2
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Periodic maintenance an d a djustment
6-12
6
6. Remove cowling C. (See page
6-7.)
7. Remove the oil filter cartridge with an oil filter wrench.
TIP
An oil filter wrench is available at a
Yamaha dealer.
8. Apply a thin coat of clean engine oil to the O-ring of the new oil filter
cartridge.
TIP
Make sure that the O-ring is properly
seated.
9. Install the new oil filter cartridge,and then tighten it to the specified
torque. 10. Install the cowling.
11. Install the engine oil drain bolts
and their new gasket, and then
tighten the bolts to the specified
torques.
12. Refill with the specified amount of the recommended engine oil.
TIP
Using a funnel is recommended.
13. After checking the engine oil fillercap O-ring, install the filler cap.
TIP
Wipe off any spilled oil before starting
the engine.
14. Start the engine and let it idle whilechecking for oil leaks.
TIP
If any oil leaks are found which you
cannot fix, have the vehicle inspected.
1. Oil filter cartridge
2. Oil filter wrench
1. O-ring
2
1
1. Torque wrench
Tightenin g torque:
Oil filter cartridge: 17 N·m (1.7 kgf·m, 13 lb·ft)
Ti ghtenin g torques:
Engine oil drain bolt (crankcase):
20 N·m (2.0 kgf·m, 15 lb·ft)
Engine oil drain bolt (oil tank): 20 N·m (2.0 kgf·m, 15 lb·ft)
1
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Periodic maintenance an d a djustment
6-13
6 15. Stop the engine, wait a few min-
utes for the oil level to settle, and
then check the oil level one last
time. NOTICE: Do not operate
the vehicle until you know that
the en gine oil level is sufficient.
[ECA10012] EAU85450
Why Yamalu
be
YAMALUBE oil is a Genuine YAMAHA
Part born of the engineers’ passion
and belief that engine oil is an impor-
tant liquid engine component. We form
teams of specialists in the fields of me-
chanical engineering, chemistry, elec-
tronics and track testing, and have
them develop the engine together with
the oil it will use. Yamalube oils take full
advantage of the base oil’s qualities
and blend in the ideal balance of addi-
tives to make sure the final oil clears
our performance standards. Thus,
Yamalube mineral, semisynthetic and synthetic oils have their own distinct
characters and value. Yamaha’s expe-
rience gained over many years of re-
search and development into oil since
the 1960’s helps make Yamalube the
best choice for your Yamaha engine.
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Periodic maintenance an d a djustment
6-14
6
EAU20028
Final gear oil
The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the vehicle. In ad-
dition, the final gear oil level must be
checked and the oil changed as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
WARNING
EWA10371
 Make sure that no forei gn mate-
rial enters the final gear case.
 Make sure that no oil gets on
the tire or wheel.
To check the final gear oil level
1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.
TIP
Make sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult in a false reading.
2. Remove the final gear oil filler boltand its gasket, and then check the
oil level in the final gear case.
TIP
The oil level should be at the brim of
the filler hole.
3. If the oil is below the brim of thefiller hole, add sufficient oil of the
recommended type to raise it to
the correct level.
4. Check the gasket for damage, and replace it if necessary.
5. Install the final gear oil filler bolt and its gasket, and then tighten
the bolt to the specified torque.
To chan ge the final g ear oil
1. Place an oil pan under the final gear case to collect the used oil.
2. Remove the final gear oil filler bolt, the final gear oil drain bolt and
their gasket to drain the oil from
the final gear case.
1. Final gear oil filler bolt
2. Gasket
3. Correct oil level
Tightenin g torque:
Final gear oil filler bolt:
23 N·m (2.3 kgf·m, 17 lb·ft)
12
3
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Periodic maintenance an d a djustment
6-15
6 3. Install the final gear oil drain bolt
and its new gasket, and then tight-
en the bolt to the specified torque.
4. Refill with the recommended final gear oil to the brim of the filler
hole.
5. Check the oil filler bolt gasket for damage, and replace it if neces-
sary.
6. Install the oil filler bolt and its gas- ket, and then tighten the bolt to
the specified torque. 7. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
1. Final gear oil filler bolt
2. Final gear oil drain bolt
3. Gasket
Tightenin g torque:
Final gear oil drain bolt:
23 N·m (2.3 kgf·m, 17 lb·ft)
Recommen ded final gear oil:
Yamaha genuine shaft drive gear oil
SAE 80W-90 API GL-5 or SAE 80
API GL-4 Hypoid gear oil
Oil quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt)
Ti ghtenin g torque:
Final gear oil filler bolt: 23 N·m (2.3 kgf·m, 17 lb·ft)
23
1
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Periodic maintenance an d a djustment
6-16
6
EAUS1203
Coolant
The coolant level should be checked
regularly. In addition, the coolant must
be changed at the intervals specified in
the periodic maintenance chart.
TIP
If genuine Yamaha coolant is not avail-
able, use an ethylene glycol antifreeze
containing corrosion inhibitors for alu-
minum engines and mix with distilled
water at a 1:1 ratio.
EAU20097To check the coolant level
Since the coolant level varies with en-
gine temperature, check when the en-
gine is cold.
1. Park the vehicle on a level surface.
2. With the vehicle in an upright posi- tion, look at the coolant level in the
reservoir. 3. If the coolant is at or below the
minimum level mark, remove the
coolant reservoir cap. WARNING!
Remove only the coolant reser-
voir cap. Never attempt to re-
move the ra diator cap when the
en gine is hot.
[EWA15162]
4. Add coolant to the maximum level
mark. NOTICE: If coolant is not
availab le, use distille d water or
soft tap water instead . Do not
use har d water or salt water
since it is harmful to the en gine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possi ble, other-
wise the coolin g system will not
b e protecte d a gainst frost an d
corrosion. If water has been
a dd ed to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possi ble, otherwise the
effectiveness of the coolant will
b e red uced.
[ECA10473]
5. Install the coolant reservoir cap.
EAU33032Chan gin g the coolant
The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Recommen ded coolant:
YAMALUBE coolant
Coolant quantity: Coolant reservoir (max 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)
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
2
13
1. Coolant reservoir cap
1
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Periodic maintenance an d a djustment
6-17
6 Yamaha dealer change the coolant.
WARNING! Never attempt to remove
the ra diator cap when the en gine is
hot.
[EWA10382] EAU36765
Air filter element
The air filter element must be replaced
at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the air
filter element.
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