2010 YAMAHA XT1200Z brake fluid

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
2-2
2
EAU10420
Right view
2
1
43
85
6
7
9
14 11 13 12 10
1. Rear brake fluid reservoir (page 6-22)
2. Shock absorber assembly spring preload adjusting knob (page 3-30)
3. Front fork rebound damping force adjusting screw (page 3-28)
4. Front fork spring preload adjusting bolt (page 3-28)
5. Main fuse (page 6-29)
6. ABS motor fuse (page 6-29)
7. Fuse box (page 6-29)
8. Front fork compression damping force adjusting screw (page 3-28) 9. Owner
’s tool kit (page 6-1)
10.Battery (page 6-28)
11.Engine oil filler cap (page 6-11)
12.Engine oil level check window (page 6-11)
13.Brake pedal (page 3-19)
14.Shock absorber assembly rebound damping force adjusting knob (page 3-30)
U23PE0E0.book Page 2 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

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner ’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel 
Check fuel level in fuel tank.
 Refuel if necessary.
 Check fuel line for leakage.
 Check the fuel tank breather/overflow hose for obstructions, cracks or damage,
and check the hose connection. 3-23, 3-24
Engine oil 
Check oil level in oil tank.
 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 level in reservoir.
 If necessary, add recommended coolant to specified level.
 Check cooling system for leakage. 6-15
Front 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
U23PE0E0.book Page 1 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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 *Air filter element Replace. √
2 *Clutch 
Check operation, fluid level and
vehicle for fluid leakage. √√√√√
3 *Front brake 
Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
 Replace brake pads. 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. √√√√√
 Replace. Every 4 years
6 *Wheels 
Check runout, spoke tightness
and for damage.
 Tighten spokes if necessary. At the initial 1000 km (600 mi) and every 5000 km (3000 mi) thereafter.
7 *Tires 
Check tread depth and for dam-
age.
 Replace if necessary.
 Check air pressure.
 Correct if necessary. √√√√√
8 *Wheel bearings 
Check bearing for looseness or
damage. √√√√
U23PE0E0.book Page 4 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU36771
TIP

Air filter This model ’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
 The air filter element needs to be replaced more frequently 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 cracked or damaged.
U23PE0E0.book Page 7 Wednesday, March 3, 2010 2:29 PM

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
U23PE0E0.book Page 22 Wednesday, March 3, 2010 2:29 PM