Yamaha Xt1200ZB Owner'S Manual Download Page 64

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-7

EAU36771

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.

U23PE2E0.book Page 7 Monday, August 1, 2011 4:25 PM

Summary of Contents for Xt1200ZB

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

Page 2: ...ER 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 2006 A11 2009 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC 1 2 3 4 Version up the norm of EN60950 to EN60950 1 To change company name version up of the following norm EN300 330 ...

Page 3: ...y 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 team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur ren...

Page 4: ...ential 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 serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING ...

Page 5: ...MANUAL 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 Japan U23PE2E0 book Page 2 Monday August 1 2011 4 25 PM ...

Page 6: ...Starting 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 the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing cowlings 6 8 Checking the spark plugs 6 10 Engine oil and oil filter cartridge 6 11 Final gear oil...

Page 7: ...ht 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 37 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U23PE2E0 book Page 2 Monday August 1 2011 4 25 ...

Page 8: ...passenger 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 who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when...

Page 9: ...heavy 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 cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem become very hot during or af ter operation and can cause burns A passe...

Page 10: ...li 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 Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any large or heavy items to the handlebar front fork o...

Page 11: ...or 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 Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles Certain acces...

Page 12: ...tie 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 parts that could break Choose the lo cation for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie down...

Page 13: ...rrier 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 oil drain bolt crankcase page 6 11 11 Engine oil filter cartridge page 6 11 U23PE2E0 book Page 1 Monday August 1 2011 4 25 PM ...

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 2 10 Battery page 6 28 11 Engine oil filler cap page 6 11 12 Engine oil level check window page 6 11 13 Brake pedal page 3 19 14 Shock absorber assembly rebound damping force adjusting knob page 3 3...

Page 15: ...page 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 lever page 3 18 9 Throttle grip page 6 17 10 Main switch steering lock page 3 3 U23PE2E0 book Page 3 Monday August 1 2011 4 25 PM ...

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 Immobilizer system This vehicle is equipped with an immo bilizer system to help prevent theft by re registering codes in the standard keys This system consists of the fol lowing a code re registerin...

Page 17: ...ed 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 tering key in a safe place Do not submerse any key in wa ter Do not expose any key to exces sively high temperatures Do not place any key close to magnets this includes but not limited to products such as...

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 systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of ...

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 trouble warning light 2 Oil level warning light 3 Traction control system indicator warning light TCS 4 Left turn signal indicator light 5 Anti lock Brake System ABS warning light 6 High beam indica...

Page 20: ...unction 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 until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU49424 Coolant temperature warning...

Page 21: ...104 242 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 Above 250 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 38 U23PE2E0 book Page 6 Monday August 1 2011 4 25 PM ...

Page 22: ...gen 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 turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have...

Page 23: ...ashing 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 device EAU49606 Multi function meter unit WARNING EWA12422 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing 1 Traction control system indicator warni...

Page 24: ...elf 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 unit TIP To use the left and right buttons the key must be turned to ON except for the brightness mode For the U K only To switch the speedometer and odometer trip meter fuel consumption displays betwee...

Page 25: ...ting 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 flashing If you do not reset the fuel reserve tripmeter manually it resets itself automatically and the dis play returns to the prior mode after re fueling and traveling 5 km 3 mi Clock The clock displays...

Page 26: ...n 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 km L or L 100 km and the average fuel consumption mode AVE_ _ _ km L or AVE_ _ _ L 100 km in the following order air intake temperature coolant tem perature km L or L 100 km AVE_ _ _ km L or AVE_ _ ...

Page 27: ...s 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 100 km or MPG for the UK only show the fuel consumption under the current riding conditions The km L display shows the dis tance that can be traveled on 1 0 L of fuel The L 100 km display shows the a...

Page 28: ...m 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 of the displays is shown To reset the average fuel consumption display select it by pushing the right button and then push the right button for at least one second while the dis play is flashing TIP ...

Page 29: ...IP 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 registering key to start the engine TIP Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys...

Page 30: ...sh 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 the selected brightness level The dis play returns to the odometer or tripmeter mode EAU12331 Anti theft alarm optional This model can be equipped with an optional anti theft alarm by a Yamaha dealer ...

Page 31: ...d 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 throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU42340 The engine trouble warning...

Page 32: ...r 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 is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly fo...

Page 33: ...bar 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 brake are applied For full braking perfor mance apply both the brake lever and the brake pedal simultaneously The unified brake system is monitored by an ECU which disables unified braking and resumes c...

Page 34: ...ed 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 away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU49481 Brake pedal The brake pedal is on the right side of the mo...

Page 35: ...and 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 in the usual way A pulsating action may be felt at the brake lever or brake pedal but this does not indicate a mal function This ABS has a test mode which allows the owner to experience the pulsatin...

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 be automatically disabled in some riding conditions see Resetting on page 3 22 When the key is turned to ON the traction control system is enabled and TCS 1 displays in the multi function meter The ...

Page 37: ...ystem 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 trouble warning light still remain on after resetting the motorcy cle may still be ridden however have a Yamaha dealer check the motorcycle as soon as possible EAU13074 Fuel tank cap To open the fuel ta...

Page 38: ...ition 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 fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ately N...

Page 39: ...damaged 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 equipped with a catalytic converter in the exhaust system WARNING EWA10862 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards...

Page 40: ...e 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 in place 2 Remove the key TIP Make sure that the rider seat is properly secured before riding The rider seat height can be ad justed to change the riding posi tion See Adjusting the rider seat height...

Page 41: ...t 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 change the rider seat height to the high position 1 Remove the rider seat See page 3 25 2 Remove the rider seat height posi tion adjuster by pulling it out 1 Low position 2 High position 1 2 1 Rider s...

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 tighten the screws to the specified torque EWA15510 1 Rider seat height position adjuster 1 Rider seat height position adjuster 2 H mark 3 Match mark 1 2 3 1 1 Projection 2 Seat holder B for high po...

Page 43: ...om 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 and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in ...

Page 44: ...may 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 be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary Spring preload setting Minimum soft 8 Standard 5 5 Maximum hard 0 1...

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 b TIP To obtain a precise adjustment it is ad visable to check the actual total number of clicks or turns of each damping force adjusting mechanism This adjustment range may not exactly match the spe...

Page 46: ...hock 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 additional carrier extends the loading surface and the loading capac ity of the standard carrier To use the additional carrier consult a Yamaha dealer Standard carrier Additional carrier WARNING EWA15481...

Page 47: ...xpla 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 otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfill...

Page 48: ...mission 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 cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure U...

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 should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be ...

Page 50: ...ay 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 only be used when the engine is run ning To use the auxiliary DC jack 1 Turn the key to OFF 2 Remove the auxiliary DC jack cap 3 Turn the accessory off 4 Insert the accessory plug into the auxiliary DC...

Page 51: ...el 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 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 Final gear oil Check vehicle for oil leakage 6 14 Coolant Check coolant lev...

Page 52: ...e 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 pressure Correct if necessary 6 18 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth...

Page 53: ...ATION 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 Monday August 1 2011 4 25 PM ...

Page 54: ...n 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 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear w...

Page 55: ...r 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 shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA...

Page 56: ...ce 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 EAU17123 0 1000 km 0 600 mi Avoid prolonged operation above 3900 r min NOTICE After 10...

Page 57: ...nd 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 overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire U23PE2E0 book Page 4 Monday August 1 2011 4 25 PM ...

Page 58: ...n 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 while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 1 2 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers ...

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 torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner...

Page 60: ...cial 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 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Ever...

Page 61: ...ace 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 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary At the initial 1000 km 600 mi and every 5000 km 3000 mi th...

Page 62: ...rake 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 Sidestand center stand Check operation Lubricate with lithium soap based grease 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leak age 19 Shock absorber as sembly Check opera...

Page 63: ...y 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 Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 28 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READ...

Page 64: ...ntly 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...

Page 65: ...ve 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 EAU49520 Cowling 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 2 1 Cowling C 1 Cowling A 2 Quick faste...

Page 66: ...cowling 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 bolts and the nuts 1 Cowling B 2 Bolt 1 Quick fastener 2 1 2 1 1 Cowling C 2 Nut 3 Bolt 2 3 1 1 Cowling C 2 Nut 3 Bolt 1 2 3 U23PE2E0 book Page 9 Monday August 1 2011 4 25 PM ...

Page 67: ...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 estim...

Page 68: ...de 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 to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Place the vehicle on a level sur face 2 Start the engine warm it up for several minutes and then turn...

Page 69: ...le 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 an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt crankcase 2 Gasket 1 2 1 Oil filter cartridge 2 Oil filter wrench 2 1 1 O ring U23PE2E0 ...

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 go off if the oil level is sufficient NOTICE ECA10401 If the oil level warning light flickers or remains on even if the oil level is correct immediately turn the engine off and have a Yamaha dealer ch...

Page 71: ...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 the fill er hole add sufficient oil of the rec ommended 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 change the final gear oil ...

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 false reading 2 Check the coolant level in the cool ant reservoir TIP The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove t...

Page 73: ...rosion 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 EAU33031 Changing the coolant The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant WARNING Never attempt t...

Page 74: ...throttle 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 fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Engi...

Page 75: ...ved 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 tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately TIP The tire tread depth limits ma...

Page 76: ...wheels 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 make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a ride After extensive tests...

Page 77: ...a 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 cessive 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 hy draulic system have a Yamaha dealer bleed the sys...

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 Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear in...

Page 79: ...ng 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 EWA16010 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may al low air to enter the brake sys tem reducing braking performance Clean the fill...

Page 80: ...r 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 for leakage If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before further riding EAU22751 Changing the brake and clutch fluids Have a Yamaha dealer change the brake a...

Page 81: ...le 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 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 water entry Therefore use care not to pour ...

Page 82: ...nd 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 ...

Page 83: ...es 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 control EAUM1652 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubric...

Page 84: ...s 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 EAU45511 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintena...

Page 85: ...s 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 EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries...

Page 86: ...lead 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 install ing the battery be sure the key is turned to OFF then con nect the positive lead before connecting the negative lead ECA16840 4 After installation make sure that the battery leads are properly con ...

Page 87: ...fuse 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 Auxiliary DC jack fuse 11 Taillight fuse 12 O P option fuse 13 Spare fuse 7 8 9 12 13 13 11 10 1 2 4 5 6 3 Specified fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 7 5 A Signaling syste...

Page 88: ...ee 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 a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remo...

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 type tail brake light If the tail brake light does not come on have a Yamaha dealer check it 1 Headlight coupler 1 Headlight bulb 2 Headlight bulb holder 1 1 2 U23PE2E0 book Page 32 Monday August 1 2...

Page 90: ...ps 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 unit bolts 2 Remove the license plate light bulb socket together with the bulb by turning it counterclockwise and then pulling it out 1 Turn signal light lens 2 Screw 1 2 1 Turn signal light bulb 1 1 ...

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 replace it as follows 1 Remove the windshield by remov ing the screws 2 Remove the panel by removing the quick fasteners 1 License plate light bulb socket 1 License plate light bulb 1 1 1 Windshield 2 Scre...

Page 92: ...headlight 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 the socket 1 Panel 2 Quick fastener 1 Headlight unit cover 2 Bolt 2 1 2 2 1 1 Headlight unit 2 Headlight unit bolt 1 Headlight lead 1 2 2 1 1 Auxiliary light bulb socket 1 Auxiliary light bulb 1 1 U2...

Page 93: ...ple 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 any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitatio...

Page 94: ...ler 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 vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns ...

Page 95: ...ped 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 recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for le...

Page 96: ...r 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 in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the d...

Page 97: ...rmal 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 insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on ...

Page 98: ...ax 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 products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU49591 St...

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 and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively t...

Page 100: ...il 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 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 26 L 0 27 US qt 0 23 Imp qt Radiator capacity including all routes 1 83 L 1 93 US qt 1 61 Imp qt Air filter Air filter ...

Page 101: ...go 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 Front 225 kPa 2 25 kgf cm 33 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Spoke wheel Rim size 19M C x MT2 50 Rear wheel Wheel type Spoke wheel Rim size 17M C x MT4 00 Unified brake syste...

Page 102: ...cator 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 Immobilizer system indicator light LED Traction control system indicator warning light LED Fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 7 5 A Signaling system fuse 10 0 A Ignition fuse 2...

Page 103: ...on 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 motorcy cle with the licensing authority in your area EAU26470 Model label The model label is affixed to the frame under the rider seat See page 3 25 Record the information on this label in the space pr...

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 light 3 5 Horn switch 3 16 I Identification numbers 9 1 Ignition circuit cut off system 3 33 Immobilizer system 3 1 Immobilizer system indicator light 3 8 Indicator lights and warning lights 3 4 L Lic...

Page 105: ...7 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 1 W Wheel bearings checking 6 28 Wheels 6 20 Windshield 3 27 U23PE2E0 book Page 2 Monday August 1 2011 4 25 PM ...

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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Yamaha Xt1200ZB, Owner'S Manual

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