Yamaha XT1200ZF Page 96 Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-32

1. Remove the headlight bulb cover

by turning it counterclockwise.

2. Disconnect the headlight coupler.

3. Unhook the headlight bulb holder,

and then remove the burnt-out
bulb.

4. Place a new headlight bulb into

position, and then secure it with
the bulb holder.

5. Connect the headlight coupler.
6. Install the headlight bulb cover by

turning it clockwise.

7. Have a Yamaha dealer adjust the

headlight beam if necessary.

1. Do not touch the glass part of the bulb.

1. Headlight bulb cover

1. Headlight coupler

1. Headlight bulb
2. Headlight bulb holder

U2BSE1E0.book Page 32 Thursday, July 31, 2014 4:31 PM

Summary of Contents for XT1200ZF

Page 1: ...DIC183 XT1200Z OWNER S MANUAL Read this manual carefully before operating this vehicle 2BS 28199 EH English E ...

Page 2: ... 300 330 2 V1 5 1 2010 Technical Construction File held by YAMAHA MOTOR ELECTRONICS CO LTD 1450 6 Mori Mori machi Shuchi gun Shizuoka 437 0292 Japan R TTE Directive Article 3 1 a Safety R TTE Directive Article 3 1 b EMC R TTE Directive Article 3 2 Spectrum DECLARATION of CONFORMITY For YAMAHA MOTOR ELECTRONICS CO LTD 1450 6 Mori Mori machi Shuchi gun Shizuoka ken 437 0292 Japan Standard used for c...

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 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 rent...

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 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 N...

Page 5: ...ANUAL 2015 by Yamaha Motor Co Ltd 1st edition April 2015 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2BSEHE0 book Page 2 Thursday May 14 2015 9 37 AM ...

Page 6: ...5 1 Shifting 5 2 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 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 6 14 Coolant 6 15 A...

Page 7: ...gnal light and tail brake light 6 35 Replacing a license plate light bulb 6 35 Supporting the motorcycle 6 36 Troubleshooting 6 37 Troubleshooting charts 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 INDEX 10 1 U2BSE1E0 book Page 2 Thursday July 31 2014 4 31 PM ...

Page 8: ...ou Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks This motorcycle is designed to carry the operator and a passen ger The failure of motorists to detect and recogni...

Page 9: ...uld always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs Protective Apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The use...

Page 10: ...that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Operation of an overloaded vehicle could cause an accident When loading within this weight limit keep the following in mind Cargo...

Page 11: ... mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the per formance of your motorcycle Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control opera tion or obscure lights or reflec tors A...

Page 12: ...OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the motorcycle with 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 ...

Page 13: ...age 3 39 4 Final gear oil filler bolt page 6 14 5 Final gear oil drain bolt page 6 14 6 Coolant reservoir page 6 15 7 Shift pedal page 3 25 8 Engine oil drain bolt oil tank page 6 11 9 Engine oil drain bolt crankcase page 6 11 10 Engine oil filter cartridge page 6 11 U2BSE1E0 book Page 1 Thursday July 31 2014 4 31 PM ...

Page 14: ...5 4 Front fork spring preload adjusting bolt page 3 35 5 Fuses page 6 30 6 Fuse box page 6 30 7 Front fork compression damping force adjusting screw page 3 35 8 Owner s tool kit page 6 2 9 Battery page 6 28 10 Engine oil filler cap page 6 11 11 Engine oil level check window page 6 11 12 Brake pedal page 3 26 13 Shock absorber assembly rebound damping force adjusting knob page 3 37 U2BSE1E0 book Pa...

Page 15: ...age 3 22 3 Clutch fluid reservoir page 6 23 4 Multi function meter unit page 3 10 5 Auxiliary DC jack page 3 42 6 Front brake fluid reservoir page 6 23 7 Right handlebar switches page 3 22 8 Brake lever page 3 25 9 Throttle grip page 6 17 10 Main switch steering lock page 3 2 U2BSE1E0 book Page 3 Thursday July 31 2014 4 31 PM ...

Page 16: ...DIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required 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 co...

Page 17: ...ering EAU26812 ON All electrical circuits are supplied with power the meter lighting taillights li cense plate light and auxiliary lights come 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 EAU10662 OFF All electrical systems are off The key can be removed WARNING EWA10062 Ne...

Page 18: ...main switch and then turn it to OFF while still pushing it EAU59680 Parking The hazard lights and turn signal lights can be turned on but all other electri cal systems are off The key can be re moved The steering must be locked before the key can be turned to NOTICE ECA20760 Using the hazard or turn signal lights for an extended length of time may cause the battery to discharge 1 Push 2 Turn 1 2 1...

Page 19: ...er when rid ing on a slope or during sudden acceleration or deceleration but this is not a malfunction 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 detec tion 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 se...

Page 20: ...AU59120 ABS warning light In normal operation the ABS warning light comes on when the key is turned to ON and goes off after traveling at a speed of 10 km h 6 mi h or higher If the ABS warning light does not come on when the key is turned to ON comes on or flashes while riding does not go off after traveling at a speed of 10 km h 6 mi h or high er The ABS may not work correctly If any of the above...

Page 21: ... then go off If the indicator light does not come on initially when the key is turned to ON or if the indicator light remains on have a Yamaha dealer check the electrical circuit The self diagnosis device also detects problems in the immobilizer system circuits See page 3 21 for an expla nation of the self diagnosis device EAU59130 Cruise control system This model is equipped with a cruise control...

Page 22: ...he setting switch once will change the speed in increments of ap proximately 2 0 km h 1 2 mi h Hold ing the RES or SET side of the cruise control setting switch down will increase or decrease the speed contin uously until the switch is released You can also manually increase your traveling speed using the throttle After you have accelerated you can set a new cruising speed by pushing the SET side ...

Page 23: ...le the system is operating will turn the system off completely and erase the previously set cruising speed You will not be able to use the resume function until a new cruising speed has been set Automatic deactivation of the cruise control system The cruise control system for this mod el is electronically controlled and is linked with the other control systems The cruise control system will auto m...

Page 24: ...t cruising speed To reduce the traveling speed apply the brakes When the brakes are applied the cruise control system will become deac tivated Self diagnosis device The cruise control system will also be come deactivated when an irregularity with any of the vehicle systems is de tected The SET indicator light will go off and the indicator light will flash You will not be able to use the cruise con...

Page 25: ...cted traction control system mode an information display which shows various information such as the odometer reading a setting mode display which al lows you to set select or reset the items shown in the information display a self diagnosis device TIP Be sure to turn the key to ON be fore pushing the select switch menu switch MENU RESET button and TCS button For the UK only To switch the me ter d...

Page 26: ... segment starts flashing refuel as soon as possi ble When the key is turned to ON all dis play segments come on once in order to test the electrical circuit TIP This fuel meter is equipped with a self diagnosis system If a problem is de tected in the electrical circuit all dis play segments start flashing If this occurs have a Yamaha dealer check the electrical circuit Eco indicator This indicator...

Page 27: ... display This display indicates which drive mode has been selected Touring mode T or sports mode S For more details on the modes and on how to select them see pages 3 22 and 3 24 Traction control system mode dis play This display indicates which traction control system mode has been select ed 1 2 or OFF For more details on the modes and on how to select them refer to page 3 27 1 Neutral indicator ...

Page 28: ... set to zero When approximately 3 9 L 1 03 US gal 0 86 Imp gal of fuel remains in the fuel tank the last segment of the fuel meter starts flashing In addition the information display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the select switch switches the display between the vari ous information...

Page 29: ...et to the information display See Setting mode on page 3 16 for de tailed information Air intake temperature display The air intake temperature display indi cates the temperature of the air drawn into the air filter case This display shows the air intake tem perature from 9 C to 93 C in 1 C in crements The temperature displayed may vary from the ambient tempera ture TIP 9 C will be displayed even ...

Page 30: ...se the select switch to select the information display that contains the average fuel consumption display Push the RESET button briefly so that the average fuel consumption dis play flashes and then push the RE SET button again for at least 2 seconds while the display is flashing TIP After resetting the average fuel con sumption display _ _ _ will be shown for that display until the vehicle has tr...

Page 31: ...l Reset 1 Display Description This function allows you to check and reset the OIL oil change interval dis tance traveled and the FREE 1 and FREE 2 maintenance intervals Maintenance This function allows you to check and reset the TIME 2 and TIME 3 functions These time trips show the total elapsed time that the key has been in the ON position When the key is turned to OFF the time trips stop count i...

Page 32: ...and TIME 3 To reset a time trip push the RE SET button to select the item to reset 3 While the selected item is flashing push the RESET button for at least 2 seconds 4 Push the menu switch MENU to return to the setting mode menu Selecting the units 1 Use the select switch to highlight Unit This function allows you to set the clock This function allows you to reset all items except the odometer and...

Page 33: ...n sumption units To set the fuel con sumption units proceed as follows If mile was selected skip steps 5 and 6 5 Use the select switch to select km L or L 100km 6 Push the menu switch MENU use the select switch to select L 100km or km L and then push the menu switch MENU again 7 Use the select switch to highlight and then push the menu switch MENU to return to the setting mode menu Selecting the d...

Page 34: ...push the menu switch MENU to return to the previous display 6 Use the select switch to highlight and then push the menu switch MENU to return to the setting mode menu Adjusting the meter panel brightness 1 Use the select switch to highlight Brightness 2 Push the menu switch MENU MENU Maintenance Time Trip Unit Display Brightness Clock All Reset Display Display 1 Display 2 Display 3 Display 1 1 1 A...

Page 35: ...gits start flash ing 5 Use the select switch to set the minutes 6 Push the menu switch MENU to return to the setting mode menu Resetting all of the display items 1 Use the select switch to highlight All Reset 2 Push the menu switch MENU 3 Use the select switch to highlight YES and then push the menu switch MENU TIP The odometer and the clock cannot be reset Brightness MENU Maintenance Time Trip Un...

Page 36: ...aused by transponder interference If this error appears try the following 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 may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it ...

Page 37: ...he drive mode switch Touring mode T The touring mode T is suitable for various riding conditions This mode allows the rider to 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 EAU1234H Handlebar switches Left 1 Drive mode switch MODE MODE STOP RUN STA RT 1 ...

Page 38: ...e throttle cable is stuck EAU42342 The engine trouble warning light and ABS warning light may come on when the key is turned to ON and the start switch is pushed but this does not in dicate a malfunction EAU12735 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an em...

Page 39: ...he clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar grip To engage the clutch re lease the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch lever position adjusting dial To adjust the distance between the clutch lever and the handlebar grip turn the adju...

Page 40: ... is being applied and the unified brake system is en abled but this does not indicate a malfunction The unified brake system does not function until the vehicle starts moving After coming to a stop while ap plying the brake lever the unified brake system is still enabled As further squeezing of the brake le ver will not increase the braking power of the rear brake apply the rear brake should furth...

Page 41: ... you would conventional brakes If the ABS is activated a pulsating sensation may be felt at the brake lever or brake ped al In this situation continue to apply the brakes and let the ABS work do not pump the brakes as this will re duce braking effectiveness WARNING EWA16051 Always keep a sufficient distance from the vehicle ahead to match the riding speed even with ABS The ABS performs best with l...

Page 42: ...may be damaged resulting in improper performance of the ABS and the unified brake system EAU58952 Traction control system The traction control system helps maintain traction when accelerating on slippery surfaces such as unpaved or wet roads If sensors detect that the rear wheel is starting to slip uncon trolled spinning the traction control system assists by regulating engine power as needed unti...

Page 43: ... See page 6 18 Using different sized tires will prevent the traction control system from controlling tire rotation accurately Setting the traction control system WARNING EWA15441 Be sure to stop the vehicle before making any setting changes to the traction control system Changing settings while riding can distract the operator and increase the risk of an accident Push the TCS button on the multi f...

Page 44: ...e EAU13075 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the ...

Page 45: ... since fuel may deteriorate painted surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on ...

Page 46: ... 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 EAU13434 Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING EWA10863 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as gra...

Page 47: ...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 48: ...t out 3 Install the rider seat height posi tion 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 32 2 Remove the rider seat height posi tion adjuster by pulling it out 1 Low position 2 High position 1 2 1 Rider ...

Page 49: ...sitions To adjust the windshield height 1 Loosen the windshield height po sition adjusting knob on each side of the windshield until resistance is felt NOTICE Do not continue turning the knob after resis tance is felt Otherwise the knob could be damaged ECA20211 2 Pull the slide plate holders out ward and then adjust the height of the windshield 1 Rider seat height position adjuster 1 Rider seat h...

Page 50: ...rwise poor handling and loss of stability may result This front fork is equipped with spring preload adjusting bolts rebound damping force adjusting screws and compression damping force adjusting screws NOTICE ECA10102 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 th...

Page 51: ...o increase the compression damping force and thereby harden the com pression damping turn the adjusting screw on each fork leg in direction a To decrease the compression damp ing force and thereby soften the com pression damping turn the adjusting screw on each fork leg in direction b 1 Spring preload adjusting bolt 1 Distance A 1 a b 1 Spring preload setting Minimum soft Distance A 19 0 mm 0 75 i...

Page 52: ...NOTICE ECA10102 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 knob in direction a To decrease the spring preload and there by soften the suspension turn the ad justing knob in direction b NOTICE To avoid damaging the adjusting knob do not turn the adjus...

Page 53: ... fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose ...

Page 54: ...rier WARNING EWA15482 Do not exceed the maximum load of 213 kg 470 lb for the ve hicle Do not sit on and never ride with a passenger on the standard or additional carrier Do not exceed the standard car rier capacity of 5 kg 11 lb Do not exceed the additional carrier capacity of 5 kg 11 lb NOTICE ECA16822 Do not lift the vehicle by either carri er EAU49491 Luggage strap holders There are four lugga...

Page 55: ... off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU57950 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following f...

Page 56: ... 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the side of the start engine stop 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 unti...

Page 57: ...y blow or the battery may discharge This vehicle is equipped with an auxil iary 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 58: ...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 damage and check hose connections 3 30 3 31 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 leve...

Page 59: ...6 17 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 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubrica...

Page 60: ...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 EAU54171 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 61: ...heck the electrical circuit 3 Start the engine by pushing the side of the start engine stop switch If the engine fails to start release the start engine stop switch wait a few seconds and then try again Each starting attempt should be as short as possible to preserve the battery Do not crank the en gine more than 10 seconds on any one attempt NOTICE ECA11043 For maximum engine life never ac celera...

Page 62: ...e clutch lever 7 Follow the same procedure when shifting to the next higher gear TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU58270 To decelerate 1 Release the throttle and apply both the front and the rear brakes smoothly to slow the motorcycle 2 At the recommended shift points shown in the following table shift to a lower gear 3 When the motorcycle ...

Page 63: ...e than the period between 0 and 1600 km 1000 mi For this reason you should read the fol lowing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engi...

Page 64: ...have a Yamaha dealer check the vehi cle EAU17214 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10312 Since the engine and 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 ...

Page 65: ...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 EWA15461 Brake discs calipers dr...

Page 66: ...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 67: ...al tools data and tech nical skills EAU46911 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 Every...

Page 68: ...ds 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 Brake fluid Replace Every 2 years 7 Wheels Check rim runout and spokes for damage Tighten all spokes At the initial 1000 km 600 mi and every 5000 km ...

Page 69: ...e 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with silicone grease 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leak age 20 Shock absorber as sembly Check operation an...

Page 70: ...l gear oil Check oil level and vehicle for oil leakage Change 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 29 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK ...

Page 71: ...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 72: ...l ing needs to be removed and installed EAU55960 Cowling 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 1 Cowling A 2 Cowling B 1 2 1 Cowling C 1 1 Cowling A 2 Quick fastener screw 1 Projection 2 Matching hole 3 Cowling B 2 2 1 1 2 3 U2BSE1E0 book Page 8...

Page 73: ... ing off 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 Cowling C To remove the cowling Remove the bolts and the nuts and then take the cowling off 1 Cowling B 2 Bolt 2 1 2 1 Quick fastener 1 1 Cowling C 2 Nut 3 Bolt 1 Cowling C 2 Nut 3 Bolt 2 3 1 1 2 3 U2BSE1E0 book Page 9 Thursday July 31 2014 4 31 PM ...

Page 74: ...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 ...

Page 75: ...ion chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 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 until the oil set tles and then check the oil level through ...

Page 76: ... Skip steps 7 11 if the oil filter cartridge is not being replaced 7 Remove cowling C See page 6 8 8 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 9 Apply a thin coat of clean engine oil to the O ring of the new oil filter cartridge 1 Engine oil drain bolt oil tank 2 Gasket 1 2 1 Engine oil drain bolt crankcase 2 Gasket 1 2 1 Oil...

Page 77: ... and exhaust sys tem have cooled down NOTICE ECA11621 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torques Engine oil drain bol...

Page 78: ...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 foreign 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...

Page 79: ...s specified in the periodic maintenance and lubrication chart EAU20095 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion TIP The coolant level must be checked on a cold engine since the level varies with engine tem perature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result ...

Page 80: ...her wise the cooling system will not be protected against frost and corrosion 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 ECA10473 EAU33032 Changing the coolant The coolant must be changed at the in tervals specified in the periodic main tenance and lubricatio...

Page 81: ...ine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21385 Checking the throttle grip free play The throttle grip free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the inner edge of the throttle grip Periodi cally check the throttle grip free play and if necessary have a Yamaha deal er adjust it Engine idling speed 1050 1150 r min 1 Throttle gr...

Page 82: ...justed before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passe...

Page 83: ...er who has the necessary professional knowl edge and experience to do so Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This model is equipped with tubeless tires and tire air valves Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and sid...

Page 84: ...ly 100 km 60 mi after installing a new tire The tires must be warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions EAU49712 Spoke wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warp age or other damage ...

Page 85: ...m have a Yamaha deal er bleed the system before operating the motorcycle EAU37914 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have ...

Page 86: ... chart EAU36891 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 indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads...

Page 87: ...efill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water or dust does not enter the brake fluid reservoir when refilling Water will significantly lower the boil ing point of the fluid and may re sult in vapor lock and dirt may clog the ABS hydraulic unit valves NOTICE ECA17641 Brake fluid may damage painted surfac...

Page 88: ...every two years Brake and clutch hoses Replace every four years EAU23115 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is s...

Page 89: ...edal pivots should be lu bricated if necessary Brake pedal Shift pedal EAU43602 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 U2BSE1E0 book Page 25 Thursday July 31 2014 4 31 PM ...

Page 90: ... have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAUM1653 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 lubricant Silicone grease Recommended lubricant Lithi...

Page 91: ...nt fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23284 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 periodic maintenance and lubrication chart 1 Place a...

Page 92: ... EAU34226 Battery The battery is located behind cowling A See page 6 8 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tight ened WARNING EWA10761 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes sever...

Page 93: ...sories NOTICE ECA16522 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turn...

Page 94: ... a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15132 1 ABS motor fuse 2 ABS motor spare fuse 3 Main fuse 4 Spare fuse 5 Cruise control fuse 6 Brake light fuse 7 Fuse box 1 2 3 5 4 6 7 1 Headlight fuse 2 ABS solenoid fuse 3 Electronic throttle valve fuse 4 Fuel injection system fuse 5 Backup fuse for clock and immobilize...

Page 95: ...nd 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 Specified fuses Main fuse 50 0 A Headlight fuse 20 0 A Brake light fuse 1 0 A Parking l...

Page 96: ...lace a new headlight bulb into position and then secure it with the bulb holder 5 Connect the headlight coupler 6 Install the headlight bulb cover by turning it clockwise 7 Have a Yamaha dealer adjust the headlight beam if necessary 1 Do not touch the glass part of the bulb 1 Headlight bulb cover 1 1 Headlight coupler 1 Headlight bulb 2 Headlight bulb holder 1 1 2 U2BSE1E0 book Page 32 Thursday Ju...

Page 97: ...nel by removing the screws and the quick fastener screw 4 Remove the headlight unit cover by removing the bolts 5 Remove the headlight unit bolts then pull the headlight unit slightly out making sure that it remains supported NOTICE Be careful not to pull the headlight leads ECA16811 1 Windshield 2 Screw 1 2 2 1 Cover 1 Panel 2 Screw 3 Quick fastener screw 1 3 2 2 1 1 Headlight unit cover 2 Bolt 1...

Page 98: ... Install the headlight unit cover by installing the bolts 12 Install the panel by installing the screws and the quick fastener screw 13 Install the cover 14 Install the windshield by installing the screws and then tightening them to the specified torque WARNING A loose windshield could cause an accident Be sure to tighten the screws to the specified torque EWA15511 1 Headlight lead 1 Auxiliary lig...

Page 99: ...e the license plate light unit bolts 2 Remove the license plate light bulb socket together with the bulb by turning it counterclock wise and then pulling it out 3 Remove the burnt out bulb by pulling it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in and then turning it clockwise until it stops 1 License plate light unit 2 License plate light un...

Page 100: ...ce A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel o...

Page 101: ...quire 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 Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWA15142 When checking the fuel system do not smoke and m...

Page 102: ...Have a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The engine does not sta...

Page 103: ...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 recommended cool ant 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 104: ...the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers 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 105: ...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 roads during winter are extremely corrosive in combination with water c...

Page 106: ... or covering it WARNING EWA11132 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering b...

Page 107: ... spark plugs and then place the spark plugs on the cylinder head so that the elec trodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark ...

Page 108: ...MOTORCYCLE CARE AND STORAGE 7 5 7 TIP Make any necessary repairs before storing the motorcycle U2BSE1E0 book Page 5 Thursday July 31 2014 4 31 PM ...

Page 109: ...h oil 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 80W 90 API GL 5 or SAE 80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18 Imp qt Coolant quantity Coolant reservoir up to the maximum 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 Air filter Air filter element O...

Page 110: ...kg 0 198 lb Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition 90 213 kg 198 470 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 system Operation Activated by front brake Front brake Type Dual disc brake Operation Rig...

Page 111: ... LED Engine trouble warning light LED ABS warning light LED Cruise control SET indicator light LED Cruise control ON indicator 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 Brake light fuse 1 0 A Signaling system fuse 7 5 A Ignition fuse 20 0 A Parking lighting fuse 7 5 A Radiator fan motor fuse 20 ...

Page 112: ...AL NUMBER MODEL LABEL INFORMATION EAU26401 Vehicle identification number The vehicle identification 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 EAU26442 Engine serial number The engine serial num...

Page 113: ...s affixed to the frame under the rider seat See page 3 32 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer U2BSE1E0 book Page 2 Thursday July 31 2014 4 31 PM ...

Page 114: ... tank cap 3 29 Fuses replacing 6 30 H Handlebar switches 3 22 Hazard switch 3 23 Headlight bulb replacing 6 31 High beam indicator light 3 4 Horn switch 3 23 I Identification numbers 9 1 Ignition circuit cut off system 3 40 Immobilizer system 3 1 Immobilizer system indicator light 3 6 Indicator lights and warning lights 3 4 L License plate light bulb replacing 6 35 Luggage strap holders 3 39 M Mai...

Page 115: ...5 Troubleshooting 6 37 Troubleshooting charts 6 38 Turn signal indicator lights 3 4 Turn signal light and tail brake light 6 35 Turn signal switch 3 23 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheels 6 20 Windshield 3 34 U2BSE1E0 book Page 2 Thursday July 31 2014 4 31 PM ...

Page 116: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 117: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 118: ...DIC183 PRINTED ON RECYCLED PAPER Original instructions PRINTED IN JAPAN 2015 05 0 3 1 CR E ...

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Yamaha XT1200ZF, Owner'S Manual

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