YAMAHA XT1200ZE 2019 Manual PDF

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 ped
al 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, center-
stan 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 a
bsor ber
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 *Coolin 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
0.66121824
UBP9E1E0.book Page 5 Friday, September 7, 2018 10:01 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 ca ble • Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous- ing, cable and grip warmer
wire. √√√√√
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
0.6 6 12 18 24
UBP9E1E0.book Page 6 Friday, September 7, 2018 10:01 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
UBP9E1E0.book Page 7 Friday, September 7, 2018 10:01 AM

Periodic maintenance an d a djustment
6-8
6
To install the cowling
1. Place the cowling in the originalposition, 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
UBP9E1E0.book Page 8 Friday, September 7, 2018 10:01 AM

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 back an d forth
while pullin g it out; to install it, twist
it back an d forth while pushin g it in.
Specified 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 ghtenin g torque:
Spark plug: 13 N·m (1.3 kgf·m, 9.6 lb·ft)
UBP9E1E0.book Page 9 Friday, September 7, 2018 10:01 AM

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.
EAU49508
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 add itives. Do
not use oils with a d iesel speci-
fication of “CD” or oils of a hi gh-
er quality than specified . In
a ddition, 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. Place the vehicle on the center- stand. A slight tilt to the side can
result in a false 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)
UBP9E1E0.book Page 10 Friday, September 7, 2018 10:01 AM

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
UBP9E1E0.book Page 11 Friday, September 7, 2018 10:01 AM

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
Tightening torque:
Oil filter cartridge: 17 N·m (1.7 kgf·m, 13 lb·ft)
Ti ghtening 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
UBP9E1E0.book Page 12 Friday, September 7, 2018 10:01 AM

Periodic maintenance an d a djustment
6-13
6
15. Stop the engine, wait a few minu-
tes 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.
UBP9E1E0.book Page 13 Friday, September 7, 2018 10:01 AM

Periodic maintenance an d a djustment
6-14
6
EAU20017
Final g ear 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 g ear case.
 Make sure that no oil gets on
the tire or wheel.
To check the final gear oil level
1. Place the vehicle on the center- stand.
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 gear oil
1. Place the vehicle on a level surfa- ce.
2. Place an oil pan under the final gear case to collect the used oil.
3. 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
Tightening torque:
Final gear oil filler bolt:
23 N·m (2.3 kgf·m, 17 lb·ft)
12
3
UBP9E1E0.book Page 14 Friday, September 7, 2018 10:01 AM