Yamaha XTZ12D(C) Owner'S Manual Download Page 92

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-36

EAU49624

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.

3. Remove the headlight unit cover

by removing the bolts.

4. 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.

[ECA16810]

1. Windshield

2. Screw

1. Panel
2. Quick fastener

1. Headlight unit cover
2. Bolt

1. Headlight unit
2. Headlight unit bolt

1. Headlight lead

U23P11E0.book Page 36 Tuesday, August 7, 2012 4:57 PM

Summary of Contents for XTZ12D(C)

Page 1: ...DIC183 23P 28199 11 XTZ12D C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 26 46...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U23P11E0 book Page 1 Tuesday August 7 2012 4 57 PM...

Page 3: ...tain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha co...

Page 4: ...tial 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: ...otor Corporation U S A 1st edition August 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed i...

Page 6: ...1 Shifting 6 2 Engine break in 6 4 Parking 6 4 PERIODIC MAINTENANCE AND ADJUSTMENT 7 1 Owner s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubr...

Page 7: ...ry light bulb 7 36 Troubleshooting 7 38 Troubleshooting charts 7 39 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 4 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identifica...

Page 8: ...They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is avai...

Page 9: ...leaner gasoline or solvent will damage windshield Use neutral detergent NOTICE WARNING 4C8 2118K 00 BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTOR...

Page 10: ...LS 1 3 1 NEVER ride as a passenger if the passenger seat and grips are removed 23P 2816J 10 WARNING NOTICE Do not lift here carrier may be damaged 23P 2815T 10 WARNING 9 7 6 8 U23P11E0 book Page 3 Tue...

Page 11: ...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 vehicle properly increases the possibili...

Page 12: ...ld 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 fee...

Page 13: ...rgo 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 accesso...

Page 14: ...mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory...

Page 15: ...FF 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 mode...

Page 16: ...ge 4 28 4 Final gear oil filler bolt page 7 15 5 Final gear oil drain bolt page 7 15 6 Coolant reservoir page 7 16 7 Shift pedal page 4 15 8 Engine oil drain bolt oil tank page 7 12 9 Engine oil drain...

Page 17: ...pring preload adjusting bolt page 4 25 5 Main fuse page 7 31 6 ABS motor fuse page 7 31 7 Fuse box page 7 31 8 Front fork compression damping force adjusting screw page 4 25 9 Owner s tool kit page 7...

Page 18: ...ge 4 13 3 Clutch fluid reservoir page 7 25 4 Multi function meter unit page 4 6 5 Auxiliary DC jack page 4 32 6 Front brake fluid reservoir page 7 24 7 Right handlebar switches page 4 13 8 Brake lever...

Page 19: ...lly 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 th...

Page 20: ...rcuit 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 tu...

Page 21: ...stop the engine immediately and allow the en gine to cool 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 the...

Page 22: ...4 242 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...

Page 23: ...ght does not go off after traveling at a speed of 10 km h 6 mi h or higher or if the warning light comes on or flashes while riding the brake system re verts to conventional braking If ei ther of the...

Page 24: ...an air intake temperature display a coolant temperature display a fuel consumption display instan taneous and average consumption functions a drive mode display which shows the selected drive mode a t...

Page 25: ...one 7750 r min and above Odometer and tripmeter modes Pushing the left button switches the dis play between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO T...

Page 26: ...the minute digits start flashing 4 Push the right button to set the minutes 5 Push the left button the clock starts after the button is released Fuel meter The fuel meter indicates the amount of fuel...

Page 27: ...ake temperature mode The air intake temperature display indi cates the temperature of the air drawn into the air filter case TIP Even when the air intake temperature mode is selected in the case of en...

Page 28: ...L 100 km or AVE_ _ _ MPG show the average fuel consumption since the display was last reset The AVE_ _ _ km L display shows the average distance that can be traveled on 1 0 L of fuel The AVE_ _ _ L 1...

Page 29: ...n the modes and on how to select them refer to page 4 17 Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of...

Page 30: ...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 EAU49431 D mode drive mode D mode is an el...

Page 31: ...To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position To cancel the turn signal lights push the switch...

Page 32: ...utch 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 ra...

Page 33: ...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 whi...

Page 34: ...you would conventional brakes If the ABS is activated a pulsating sensation may be felt at the brake lever or brake pedal In this situation continue to apply the brakes and let the ABS work do not pu...

Page 35: ...be damaged resulting in improper performance of the ABS and the unified brake system EAU49416 Traction control system The traction control system helps main tain traction when accelerating on slip per...

Page 36: ...ntrol system from controlling tire rotation accurately Setting the traction control system WARNING EWA15440 Be sure to stop the vehicle before making any setting changes to the traction control system...

Page 37: ...ssible EAU13074 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 re leased and the fuel tank...

Page 38: ...ce fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line...

Page 39: ...cks or damage and replace if 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 Catalyt...

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 t...

Page 43: ...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...

Page 44: ...y 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...

Page 45: ...orce 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...

Page 46: ...elf Take the shock 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...

Page 47: ...uts the ignition in certain situations See the following section for an expla nation of the ignition circuit cut off sys tem WARNING EWA10241 The vehicle must not be ridden with the sidestand down or...

Page 48: ...nctions It prevents starting when the trans 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...

Page 49: ...lutch 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 shou...

Page 50: ...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 onl...

Page 51: ...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 4 20 4 21 E...

Page 52: ...5 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 19 7 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal piv...

Page 53: ...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 EAU54801 Starting the engine In order for the ignit...

Page 54: ...t the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve t...

Page 55: ...to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear TIP When shi...

Page 56: ...oil must be changed and the oil filter cartridge or element re placed ECA10332 1000 1600 km 600 1000 mi Avoid prolonged operation above 4700 r min 1600 km 1000 mi and beyond The vehicle can now be ope...

Page 57: ...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 58: ...ncluded 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 torq...

Page 59: ...8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spar...

Page 60: ...ol system for dam age Replace if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months...

Page 61: ...id leak age Correct if necessary 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace...

Page 62: ...as teners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply silicone gr...

Page 63: ...ar tridge Replace 24 Cooling system Check coolant level and vehicle for coolant leakage Change coolant Every 3 years 25 Final gear oil Check oil level and for oil leakage Change at initial 600 mi 1000...

Page 64: ...levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the br...

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: ...wling 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 bol...

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: ...o 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...

Page 69: ...Skip steps 7 11 if the oil filter cartridge is not being replaced 7 Remove cowling C See page 7 9 8 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a...

Page 70: ...and exhaust sys tem have cooled down NOTICE ECA11620 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 diese...

Page 71: ...epair the vehicle In addi tion the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart WARNING EWA10370 Mak...

Page 72: ...ool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU40154 To check the coolant level 1 Place the vehicle on the center stand TIP The coolant level m...

Page 73: ...as soon as possible other 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 co...

Page 74: ...ne idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21384 Checking the throttle grip free play The throttle grip free play should mea sure 3 0 5 0 mm...

Page 75: ...RNING EWA10503 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 t...

Page 76: ...s 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 characteristi...

Page 77: ...ng points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or oth er damage and the spokes for looseness or damage before each ride If any damage is found have...

Page 78: ...m have a Yamaha dealer bleed the system before operating the motorcycle EAU37913 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yam...

Page 79: ...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 applyin...

Page 80: ...ill 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 refill...

Page 81: ...aged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years EAU23114 Checking and lubricating the throttle grip and cable The operation of the throttle grip shoul...

Page 82: ...dal pivots should be lu bricated if necessary Brake pedal Shift pedal EAU43601 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked befor...

Page 83: ...faces should be lubri cated if necessary WARNING EWA10741 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sides...

Page 84: ...ck the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely su...

Page 85: ...earings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn...

Page 86: ...16521 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...

Page 87: ...G Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15131 1 ABS motor fuse 2 ABS motor spare fuse 3 Main...

Page 88: ...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 Headlig...

Page 89: ...ce a new headlight bulb into po sition 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...

Page 90: ...removing the screw 2 Remove the turn signal light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket...

Page 91: ...Remove the burnt out bulb by pull ing 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 6 Place the...

Page 92: ...removing the quick fasteners 3 Remove the headlight unit cover by removing the bolts 4 Remove the headlight unit bolts then pull the headlight unit slightly out making sure that it remains supported N...

Page 93: ...torque 10 Install the headlight unit cover by installing the bolts 11 Install the panel by installing the quick fasteners 12 Install the windshield by installing the screws in the lower holes and then...

Page 94: ...uire 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 Imit...

Page 95: ...ave 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 Ya...

Page 96: ...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 97: ...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 98: ...onge 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...

Page 99: ...or covering it WARNING EWA11131 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...

Page 100: ...spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter...

Page 101: ...MOTORCYCLE CARE AND STORAGE 8 5 8 TIP Make any necessary repairs before storing the motorcycle U23P11E0 book Page 5 Tuesday August 7 2012 4 57 PM...

Page 102: ...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 80 API GL 5 or SAE 80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 1...

Page 103: ...ider passenger cargo 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 XTZ1...

Page 104: ...light 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine...

Page 105: ...tification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification nu...

Page 106: ...dering spare parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label s...

Page 107: ...and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yama...

Page 108: ...cle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed o...

Page 109: ...nder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4...

Page 110: ...MATION 10 6 10 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U23P11E0 book Page 6 Tuesday August...

Page 111: ...warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and...

Page 112: ...later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty ca...

Page 113: ...d repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is incl...

Page 114: ...ed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to hel...

Page 115: ...4 21 Fuel tank cap 4 19 Fuses replacing 7 31 H Handlebar switches 4 13 Headlight bulb replacing 7 32 High beam indicator light 4 2 Horn switch 4 13 I Identification numbers 10 1 Ignition circuit cut...

Page 116: ...n signal indicator lights 4 2 Turn signal light bulb replacing 7 34 Turn signal switch 4 13 V Valve clearance 7 19 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W...

Page 117: ...enuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and appro...

Page 118: ...PRINTED IN JAPAN 2012 08 0 7 1 CR E DIC183 PRINTED ON RECYCLED PAPER...

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