Yamaha Super Tenere XTZ1200Z Owner'S Manual Download

Page: 82 / 108

PERIODIC MAINTENANCE AND ADJUSTMENT

6-25

Brake pedal

Shift pedal

EAU43601

Checking and lubricating the
brake and clutch levers

The 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

Recommended lubricant:

Lithium-soap-based grease

Recommended lubricant:

Silicone grease

U23PE2E0.book Page 25 Monday, August 1, 2011 4:25 PM

Summary of Contents for Super Tenere XTZ1200Z

Page 1: ...DIC183 XT1200Z OWNER S MANUAL Read this manual carefully before operating this vehicle 23P 28199 E2 English E...

Page 2: ...R Hereby declare that the product Type designation 5SL 00 is in compliance with following norm s or documents R TTE Directive 1999 5 EC EN300 330 2 v1 3 1 2006 01 EN300 330 2 v1 5 1 2010 02 EN60950 1...

Page 3: ...In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha...

Page 4: ...ntial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or...

Page 5: ...ANUAL 2011 by Yamaha Motor Co Ltd 1st edition July 2011 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in...

Page 6: ...tarting the engine 5 1 Shifting 5 2 Tips for reducing fuel consumption 5 3 Engine break in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND ADJUSTMENT 6 1 Owner s tool kit 6 2 Periodic maintenance chart for t...

Page 7: ...t bulb 6 31 Tail brake light 6 32 Replacing a turn signal light bulb 6 33 Replacing a license plate light bulb 6 33 Replacing an auxiliary light bulb 6 34 Troubleshooting 6 36 Troubleshooting charts 6...

Page 8: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver...

Page 9: ...eavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and...

Page 10: ...i ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently...

Page 11: ...r front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wi...

Page 12: ...ie downs or suitable straps that are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or...

Page 13: ...rier page 3 31 5 Final gear oil filler bolt page 6 14 6 Final gear oil drain bolt page 6 14 7 Coolant reservoir page 6 15 8 Shift pedal page 3 18 9 Engine oil drain bolt oil tank page 6 11 10 Engine o...

Page 14: ...spring preload adjusting bolt page 3 28 5 Main fuse page 6 29 6 ABS motor fuse page 6 29 7 Fuse box page 6 29 8 Front fork compression damping force adjusting screw page 3 28 9 Owner s tool kit page 6...

Page 15: ...age 3 16 3 Clutch fluid reservoir page 6 22 4 Multi function meter unit page 3 8 5 Auxiliary DC jack page 3 35 6 Front brake fluid reservoir page 6 22 7 Right handlebar switches page 3 16 8 Brake leve...

Page 16: ...enjoy smooth drivability from the low speed range to the high speed range Sports mode S This mode offers a sportier engine re sponse in the low to mid speed range compared to the touring mode EAU10977...

Page 17: ...d i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re regis terin...

Page 18: ...on and the engine can be start ed The key cannot be removed TIP The headlights come on automatically when the engine is started and stay on until the key is turned to OFF EAU10661 OFF All electrical s...

Page 19: ...be turned to NOTICE ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU49391 Indicator lights and warning lights 1 Push 2 Turn 1 2 1 Engine...

Page 20: ...nction This model is also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated unt...

Page 21: ...04 242 F Coolant temperature is dis played OK Go ahead with riding 117 120 C 243 249 F Message HI flashes Stop the vehicle and allow it to idle until the coolant temperature goes down Above 121 C Abov...

Page 22: ...en cy braking If the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turnin...

Page 23: ...shing however the immobi lizer system is still enabled The self diagnosis device also detects problems in the immobilizer system cir cuits See page 3 14 for an explana tion of the self diagnosis devic...

Page 24: ...lf diagnosis device an LCD and tachometer bright ness control mode The left and right set buttons located under the display allow you to control or change the settings in the multi func tion meter uni...

Page 25: ...ing TRIP 1 TRIP 2 or TRIP F the display flashes for five seconds To reset a tripmeter select it by push ing the left button and then push this button for at least one second while the display is flash...

Page 26: ...sumption and average fuel consumption modes Push the right button to switch the dis play between the air intake tempera ture mode the coolant temperature mode the instantaneous fuel con sumption mode...

Page 27: ...the temperature of the coolant NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Instantaneous fuel consumption mode The instantaneous fuel consumption display modes km L L...

Page 28: ...For the UK only The AVE_ _ _ MPG display shows the average distance that can be traveled on 1 0 Imp gal of fuel To switch between the average fuel consumption displays push the right button when one...

Page 29: ...P If the display indicates immobilizer sys tem circuit error code 52 this could be caused by transponder interference If this error code appears try following the procedure below 1 Use the code re reg...

Page 30: ...h and hold the left button 3 Turn the key to ON and then re lease the left button after five sec onds 4 Push the right button to select the desired brightness level 5 Push the left button to confirm t...

Page 31: ...the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the thrott...

Page 32: ...sports mode S The throttle grip must be completely closed in order to change the drive mode The selected mode is shown on the drive mode display See page 3 13 EAU12830 Clutch lever The clutch lever i...

Page 33: ...ar grip To apply the front brake pull the lever toward the handle bar grip This model is equipped with a unified brake system When pulling the brake lever the front brake and a portion of the rear bra...

Page 34: ...d The brake lever is equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed aw...

Page 35: ...nd if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but these do not indicate a mal function When the ABS is activated the brakes are operated...

Page 36: ...2 Sporty mode This mode decreases traction con trol system assist allowing the rear wheel to spin more freely than TCS mode 1 TCS mode Off The traction control system is turned off The system may also...

Page 37: ...stem will be enabled The engine trouble warning light should go off after the motorcycle reaches at least 20 km h 12 mi h If the traction control system indicator light warning light and or engine tro...

Page 38: ...tion such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the...

Page 39: ...amaged Make sure that the end of each hose is not blocked and clean if necessary Make sure that the end of each hose is positioned outside of the cowling EAU13433 Catalytic converter This model is equ...

Page 40: ...rider seat and push the seat forward To install the rider seat 1 Insert the projection on the rear of the rider seat into the seat holder as shown and then push the front of the seat down to lock it...

Page 41: ...out 3 Install the rider seat height position adjuster so that the match mark is aligned with the L mark as shown 4 Insert the projection on the rear of the rider seat into seat holder A as shown To c...

Page 42: ...is removed and then reinstalled be sure to install the windshield screws in the lower holes and tighten the screws to the specified torque WARNING A loose windshield could cause an accident Be sure to...

Page 43: ...m pression damping force adjusting screws NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload To increase the spring preload an...

Page 44: ...ay not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would b...

Page 45: ...force and thereby harden the rebound damp ing turn the adjusting knob in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in di rection...

Page 46: ...ock absorber assembly to a Yamaha dealer for any service EAU49701 Carriers This motorcycle is equipped with a standard carrier and with an additional carrier located under the passenger seat This addi...

Page 47: ...pla nation of the ignition circuit cut off sys tem WARNING EWA10241 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwis...

Page 48: ...ission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It...

Page 49: ...clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not be working correctly The motorcycle sho...

Page 50: ...y blow or the battery may discharge This vehicle is equipped with an auxilia ry DC jack A 12 V accessory connected to the auxiliary DC jack can be used when the key is in the ON position and should on...

Page 51: ...l 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 dam age and check hose connections 3 23 3 24...

Page 52: ...cable and grip housing 6 17 6 24 Control cables Make sure that operation is smooth Lubricate if necessary 6 24 Wheels and tires Check for damage Check tire condition and tread depth Check air pressur...

Page 53: ...TION CHECKS 4 3 4 Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 3 32 ITEM CHECKS PAGE U23PE2E0 book Page 3 Mon...

Page 54: ...pushing the start switch an engine auto stop system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU49541 Starti...

Page 55: ...ac celerate hard when the engine is cold EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are...

Page 56: ...e 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 pe...

Page 57: ...d exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overtu...

Page 58: ...performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine whi...

Page 59: ...included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a tor...

Page 60: ...ial tools data and technical skills EAU46910 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 2...

Page 61: ...ce 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 C...

Page 62: ...ake pedal pivot shaft Lubricate with lithium soap based grease 14 Clutch lever pivot shaft Lubricate with silicone grease 15 Shift pedal pivot shaft Lubricate with lithium soap based grease 16 Sidesta...

Page 63: ...3 years 24 Final gear oil Check oil level and vehicle for oil leakage Change 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Throttle grip Check operation Che...

Page 64: ...tly 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...

Page 65: ...e 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...

Page 66: ...owling A EAU49550 Cowling 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 bo...

Page 67: ...xcessive 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 Clea...

Page 68: ...e of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it...

Page 69: ...e at a Yamaha dealer 9 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 10 Install the new oil filter cartridge with...

Page 70: ...several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause TIP After the engine is started the engine oil level warning light should g...

Page 71: ...he 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 the fill er hole add sufficient oil of the rec ommended type to raise it to the correct...

Page 72: ...checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a...

Page 73: ...osion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 E...

Page 74: ...hrottle grip Periodi cally check the throttle grip free play and if necessary have a Yamaha deal er adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fu...

Page 75: ...ed for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If the center trea...

Page 76: ...heels WARNING EWA10901 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motorcy cle may be different which could lead to an accident Always...

Page 77: ...hy draulic clutch adjusting the clutch lever free play is not needed However it is necessary to check the hydraulic sys tem for leakage before each ride If the clutch lever free play does become ex c...

Page 78: ...Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU36890 Front brake pads Ea...

Page 79: ...g check that the brake fluid is above the minimum level mark Check the brake fluid level with the top of the reservoir level Replenish the brake fluid if necessary Front brake Rear brake WARNING EWA16...

Page 80: ...the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads and or brake sys tem leakage therefore be sure to check the brake pads for wear and the brake system f...

Page 81: ...e grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart The throttle cable is equipped wi...

Page 82: ...d clutch levers The 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 Recommended lubricant L...

Page 83: ...s not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of contr...

Page 84: ...several times to check if the front fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it E...

Page 85: ...sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID E...

Page 86: ...ead ECA16302 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When instal...

Page 87: ...use 3 Electronic throttle valve fuse 4 Fuel injection system fuse 5 Backup fuse for clock and immobilizer sys tem 6 Radiator fan fuse 7 Ignition fuse 8 Signaling system fuse 9 ABS control unit fuse 10...

Page 88: ...e from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using...

Page 89: ...headlight coupler 6 Install the headlight bulb cover by turning it clockwise 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24181 Tail brake light This model is equipped with an LED...

Page 90: ...s 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 EAU49721 Replacing a license plate light bulb 1 Remove the license plate light u...

Page 91: ...light unit in the original position and then in stall the bolts EAU49623 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replac...

Page 92: ...eadlight leads ECA16810 5 Remove the auxiliary light bulb socket together with the bulb by turning the socket counterclock wise 6 Remove the burnt out bulb by pull ing it out 7 Insert a new bulb into...

Page 93: ...le can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require...

Page 94: ...er check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehi...

Page 95: ...ed press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommen...

Page 96: ...the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly...

Page 97: ...mal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insect...

Page 98: ...x to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what...

Page 99: ...the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers...

Page 100: ...l 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 80 API GL 5 or SAE 80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18...

Page 101: ...o and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition 90 209 kg 198 461 lb Fr...

Page 102: ...ator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light LED Im...

Page 103: ...n number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your mot...

Page 104: ...for reducing 5 3 Fuel tank breather hose and overflow hose 3 24 Fuel tank cap 3 22 Fuses replacing 6 29 H Handlebar switches 3 16 Hazard switch 3 17 Headlight bulb replacing 6 31 High beam indicator l...

Page 105: ...Troubleshooting 6 36 Troubleshooting charts 6 37 Turn signal indicator lights 3 5 Turn signal light bulb replacing 6 33 Turn signal switch 3 16 V Valve clearance 6 17 Vehicle identification number 9...

Page 106: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM...

Page 107: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM...

Page 108: ...PRINTED IN JAPAN 2011 08 0 3 1 CR E DIC183 PRINTED ON RECYCLED PAPER...

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