2010 YAMAHA XT1200Z clutch

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
D-mode (drive mode) ......................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-3
Indicator lights and warning lights ............................................3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-15
Handlebar switches ......................3-16
Clutch lever ...................................3-17
Shift pedal .....................................3-18
Brake lever ...................................3-18
Brake pedal ..................................3-19
ABS ..............................................3-20
Traction control system ................3-21
Fuel tank cap ................................3-22
Fuel ...............................................3-23
Fuel tank breather/overflow hose ..........................................3-24
Catalytic converter ........................3-25
Rider seat .....................................3-25
Adjusting the rider seat height ......3-26
Windshield ....................................3-28 Adjusting the front fork ................. 3-28
Adjusting the shock absorber
assembly ................................... 3-30
Carriers ........................................ 3-31
Luggage strap holders ................. 3-32
Sidestand ..................................... 3-32
Ignition circuit cut-off system ........ 3-33
Auxiliary DC jack .......................... 3-35
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1
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 ............................... 6-1
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
Air filter element ........................... 6-16
Checking the engine idling
speed ........................................ 6-17
Checking the throttle cable free play ........................................... 6-17
Valve clearance ........................... 6-17
Tires ............................................. 6-18
Spoke wheels .............................. 6-20
Clutch lever .................................. 6-20
Checking the brake lever free play ........................................... 6-20
Brake light switches ..................... 6-21
Checking the front and rear brake pads .......................................... 6-21
Checking the brake fluid level ...... 6-22
Changing the brake and clutch fluids ......................................... 6-23
Checking and lubricating the cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-24
Checking and lubricating the brake and shift pedals .............. 6-24
Checking and lubricating the brake and clutch levers ............ 6-25
Checking and lubricating the
centerstand and sidestand ....... 6-25U23PE0E0.book Page 1 Wednesday, March 3, 2010 2:29 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments
87654
321
9
10
1. Clutch lever (page 3-17)
2. Left handlebar switches (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)U23PE0E0.book Page 3 Wednesday, March 3, 2010 2:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
EAU12733
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 emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.NOTICE
ECA10061
Do not use the hazard lights for an
extended length of time with the en-
gine not running, otherwise the bat-
tery may discharge.
EAU49571
Drive mode switch “MODE ”
WARNING
EWA15340
Do not change the D-mode while the
vehicle is moving.Using this switch changes the drive
mode to touring mode “ T” or 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 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
adjusting dial while holding the lever
pushed away from the handlebar grip.1. Clutch lever
2. Clutch lever position adjusting dial
3. Arrow mark
4. Distance between clutch lever and handlebar
grip
12
34
1
4
3
2
U23PE0E0.book Page 17 Wednesday, March 3, 2010 2:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3Make sure that the appropriate setting
on the adjusting dial is aligned with the
arrow mark on the clutch lever.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-33.)
EAU12870
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU49515
Brake lever The brake lever is located at the right
handlebar 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 conventional
braking if a malfunction occurs.
WARNING
EWA15521
The unified brake system does not
shorten the braking distance. There-
fore, always keep a sufficient dis-
tance to the vehicle ahead.TIP

Resistance and vibration may be
felt in the brake pedal while the
front brake is being applied and
1. Shift pedal
1
U23PE0E0.book Page 18 Wednesday, March 3, 2010 2:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-33
3
EAU44902
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

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 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.
U23PE0E0.book Page 33 Wednesday, March 3, 2010 2:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-34
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the 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 working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.• The vehicle must be placed on the center-
stand during this inspection.• If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
U23PE0E0.book Page 34 Wednesday, March 3, 2010 2:29 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake 
Check operation.
 If soft or spongy, have Yamaha dealer bleed hydraulic system.
 Check brake pads for wear.
 Replace if necessary.
 Check fluid level in reservoir.
 If necessary, add recommended brake fluid to specified level.
 Check hydraulic system for leakage. 6-21, 6-22
Clutch 
Check operation.
 If soft or spongy, have Yamaha dealer bleed hydraulic system.
 Check hydraulic system for leakage. 6-20
Throttle grip 
Make sure that operation is smooth.
 Check cable free play.
 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing. 6-17, 6-24
Control cables 
Make sure that operation is smooth.
 Lubricate if necessary. 6-23
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.
 Lubricate lever pivoting points if necessary. 6-25
Centerstand, sidestand 
Make sure that operation is smooth.
 Lubricate pivots if necessary. 6-25
Chassis fasteners 
Make sure that all nuts, bolts and screws are properly tightened.
 Tighten if necessary. —
Instruments, lights, signals
and switches 
Check operation.
 Correct if necessary. —
ITEM CHECKS PAGE
U23PE0E0.book Page 2 Wednesday, March 3, 2010 2:29 PM

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU48710
TIPThis model is equipped with:

a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the multi-function display in-
dicates error code 30, but this is
not a malfunction. Turn the key to
“ OFF ” and then to “ ON” to clear the
error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
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.
EAU49540
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 with
the clutch lever pulled and the
sidestand up.
See page 3-33 for more informa-
tion.
1. Turn the key to “ ON” and make
sure that the engine stop switch is
set to “”.
The following warning lights and
indicator lights should come on for
a few seconds, then go off.

Oil level warning light


Engine trouble warning light


Coolant temperature warning
light


ABS warning light


Traction control system indi-
cator/warning light


Immobilizer system indicator
light
U23PE0E0.book Page 1 Wednesday, March 3, 2010 2:29 PM