2010 YAMAHA XT1200Z maintenance

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
11. Install the engine oil drain bolts
and their new gasket, and then
tighten the bolts to the specified
torques.
12. Refill with the specified amount of the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine 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 diesel speci-
fication of “ CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ ENERGY CONSERVING II ” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
13. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.TIPAfter 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 check
the vehicle.14. Turn the engine off, wait a few min-utes until the oil settles, and then
check the oil level and correct it if
necessary.
15. Install the cowling.
1. Torque wrenchTightening torque: Oil filter cartridge:17 Nm (1.7 m ·kgf, 12 ft ·lbf)
Tightening torques: Engine oil drain bolt (crankcase):
20 Nm (2.0 m ·kgf, 14 ft ·lbf)
Engine oil drain bolt (oil tank): 20 Nm (2.0 m ·kgf, 14 ft ·lbf)1
Recommended engine oil:
See page 8-1.
Oil quantity: Without oil filter cartridge replace-
ment:3.10 L (3.28 US qt, 2.73 Imp.qt)
With oil filter cartridge replacement:
3.40 L (3.59 US qt, 2.99 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
EAU20016
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair 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


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 level1. Place the vehicle on the center- stand.TIPMake sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.2. Remove the final gear oil filler boltand its gasket, and then check the
oil level in the final gear case.
TIPThe 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
1. Place the vehicle on a level sur- face.
2. Place an oil pan under the final gear case to collect the used oil.
3. Remove the final gear oil filler bolt, the final gear oil drain bolt and their
gasket to drain the oil from the final
gear case.
4. Install the final gear oil drain bolt and its new gasket, and then tight-
en the bolt to the specified torque.1. Final gear oil filler bolt
2. Gasket
3. Correct oil level
1
2
3
Tightening torque: Final gear oil filler bolt:
23 Nm (2.3 m ·kgf, 17 ft· lbf)1. Final gear oil filler bolt
2. Final gear oil drain bolt
3. Gasket
231
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
5. Refill with the recommended final
gear oil to the brim of the filler hole.
6. Check the oil filler bolt gasket for damage, and replace it if neces-
sary.
7. Install the oil filler bolt and its gas- ket, and then tighten the bolt to the
specified torque.
8. Check the final gear case for oil leakage. If oil is leaking, check for
the cause.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU40154
To check the coolant level1. Place the vehicle on the center- stand.TIP

The coolant level must be 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.TIPThe coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below theminimum level mark, remove the
coolant reservoir cap.
Tightening torque:Final gear oil drain bolt:
23 Nm (2.3 m ·kgf, 17 ft ·lbf)
Recommended final gear oil: Yamaha genuine shaft drive gear oil
SAE 80 API GL-5 or SAE 80 API
GL-4 Hypoid gear oil
Oil quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt)
Tightening torque: Final gear oil filler bolt:
23 Nm (2.3 m ·kgf, 17 ft ·lbf)
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir cap
2
1
31
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
64. Add coolant or distilled water to
raise the coolant to the maximum
level mark, install the coolant res-
ervoir cap. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the ra-
diator cap when the engine is
hot.
[EWA15161]
NOTICE: If coolant is
not available, use distilled water
or soft tap water instead. Do not
use hard water or salt water
since it is harmful to the engine.
If water has been used instead
of coolant, replace it with cool-
ant 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 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 to remove the radiator cap when the engine is
hot.
[EWA10381] EAU36764
Air filter element The air filter element must be replaced
at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the air
filter element.
Coolant reservoir capacity (up to
the maximum level mark):
0.26 L (0.27 US qt, 0.23 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
EAU44734
Checking the engine idling
speed Check the engine idling speed and, if
necessary, have it corrected by a
Yamaha dealer.
EAU21383
Checking the throttle cable
free play The throttle cable 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 cable 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.
Engine idling speed: 1050– 1150 r/min
1. Throttle cable free play
1
U23PE0E0.book Page 17 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6
EAU49672
Tires To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10501
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 ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
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.TIPThe tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire air pressure (measured on cold
tires):0– 90 kg (0 –198 lb):
Front:
225 kPa (2.25 kgf/cm ², 33 psi)
Rear: 250 kPa (2.50 kgf/cm ², 36 psi)
90 –209 kg (198 –461 lb):
Front: 225 kPa (2.25 kgf/cm ², 33 psi)
Rear: 290 kPa (2.90 kgf/cm ², 42 psi)
Maximum load*:
209 kg (461 lb)
* Total weight of rider, passenger, car- go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear): 1.6 mm (0.06 in)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
WARNING
EWA10471


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.


The replacement of all wheel
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, 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 motorcycle is equipped with spoke
wheels and tubeless tires with valves.
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, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Front tire: Size: 110/80R19M/C 59V
Manufacturer/model: BRIDGESTONE/BW501
METZELER/TOURANCE EXP C
Rear tire: Size: 150/70R17M/C 69V
Manufacturer/model: BRIDGESTONE/BW502
METZELER/TOURANCE EXP C
FRONT and REAR: Tire air valve: TR412
Va l ve c o r e : #9100 (original)
U23PE0E0.book Page 19 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
EAU49710
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 or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
EAU42850
Clutch lever Since this model is equipped with 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 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 Yamaha dealer inspect the
brake system.
WARNING
EWA14211
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 a
Yamaha dealer bleed the system be- fore operating the vehicle. Air in the
hydraulic system will diminish the1. No brake lever free play
1
U23PE0E0.book Page 20 Wednesday, March 3, 2010 2:29 PM