2010 YAMAHA XT1200Z torque

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6The service information included 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 torque
wrench may be necessary to perform
certain maintenance work correctly.
TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.U23PE0E0.book Page 2 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6
EAU19652
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive 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.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4
–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.NOTICE
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in.
Specified spark plug: NGK/CPR8EB9
1. Spark plug gapSpark plug gap:0.8 –0.9 mm (0.031 –0.035 in)
Tightening torque: Spark plug:13 Nm (1.3 m ·kgf, 9.4 ft· lbf)
U23PE0E0.book Page 10 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPSkip steps 7–10 if the oil filter cartridge
is not being replaced.7. Remove cowling C. (See page 6-8.)
8. Remove the oil filter cartridge with an oil filter wrench.
TIPAn oil filter wrench is available at a
Yamaha dealer.9. Apply a thin coat of clean engine oil to the O-ring of the new oil filter
cartridge.
TIPMake sure that the O-ring is properly
seated.10. Install the new oil filter cartridge with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
1. Engine oil drain bolt (crankcase)
2. Gasket
12
1. Engine oil filter cartridge
2. Oil filter wrench21
1. O-ring
U23PE0E0.book Page 12 Wednesday, March 3, 2010 2:29 PM

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)
U23PE0E0.book Page 13 Wednesday, March 3, 2010 2:29 PM

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
U23PE0E0.book Page 14 Wednesday, March 3, 2010 2:29 PM

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
U23PE0E0.book Page 15 Wednesday, March 3, 2010 2:29 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-35
6
supported.
NOTICE: Be careful
not to pull the headlight leads.
[ECA16810]
5. Remove the auxiliary light socket (together with the bulb) by turning
the socket counterclockwise. 6. Remove the burnt-out bulb by pull-
ing it out.
7. Insert a new bulb into the socket.
8. Install the auxiliary light socket (to- gether with the bulb) by pushing it
in and turning it clockwise. 9. Install the headlight unit by install-
ing the bolts, and then tightening
them to the specified 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, and then tightening
them to the specified torque.
WARNING! A loose windshield could cause an accident. Be
sure to tighten the screws to the
specified torque.
[EWA15510]
1. Headlight unit
2. Bolt
1. Headlight lead
1
2
2
1
1. Auxiliary light bulb socket
1. Auxiliary light bulb
1
1
Tightening torque:Headlight unit bolt: 7 Nm (0.7 m ·kgf, 5.1 ft· lbf)
Tightening torque: Windshield screw: 0.5 Nm (0.05 m ·kgf, 0.36 ft ·lbf)
U23PE0E0.book Page 35 Wednesday, March 3, 2010 2:29 PM