2010 YAMAHA XT1200Z maintenance

PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
braking performance, which may re-
sult in loss of control and an acci-
dent.
EAU36503
Brake light switches The brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, have a Yamaha deal-
er adjust the brake light switches.
EAU22392
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36890
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn to1. Brake pad wear indicator
1
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6the point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU40260
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective. Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
1. Lining thickness
11
1. Minimum level mark
1. Minimum level mark
LOWER
1
UPPER
LOWER
1
Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22751
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the TIP after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake and clutch hoses: Replace
every four years.
EAU23101
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
sheath may interfere with proper ca-
ble operation and will cause the in-
ner cable to rust. Replace a
damaged cable as soon as possible
to prevent unsafe conditions.
[EWA10721]
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAU23112
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated by a
Yamaha dealer at the intervals speci- fied in the periodic maintenance chart.
EAU44272
Checking and lubricating the
brake and shift pedals Brake pedal
Shift pedal
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant: Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAU43600
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU23213
Checking and lubricating the
centerstand and sidestand The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces 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
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Recommended lubricant:Silicone grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAUM1651
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.
EAU23272
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
Recommended lubricant:Lithium-soap-based grease
Recommended lubricant:Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45511
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.1. Place the vehicle on the center- stand. WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10751]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23291
Checking the wheel bearings 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
smoothly, have a Yamaha dealer check
the wheel bearings.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAU34224
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, tightened.
WARNING
EWA10760


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact withskin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
 EXTERNAL: Flush with plenty
of water.
 INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
 EYES: Flush with water for 15
minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
NOTICE
ECA16520
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. If
you do not have access to a con-
stant-voltage battery charger, have a
Yamaha dealer charge your 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
turned to “OFF ”, then discon-
nect the negative lead before
disconnecting the positive lead.
[ECA16302]
2. If the battery will be stored for more than two months, check it at least
once a month and fully charge it if
necessary.
1. Positive battery lead (red)
2. Negative battery lead (black)
3. Battery1
3
2
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