2011 YAMAHA XT1200Z brake pads

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 ........................3-24
Rider seat .....................................3-25
Adjusting the rider seat height ......3-26
Windshield ....................................3-27 Adjusting the front fork ................. 3-28
Adjusting the shock absorber
assembly ................................... 3-29
Carriers ........................................ 3-31
Luggage strap holders ................. 3-31
Sidestand ..................................... 3-32
Ignition circuit cut-off system ........ 3-32
Auxiliary DC jack .......................... 3-34
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 ............................... 6-2
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 grip 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 ....... 6-25U23PE1E0.book Page 1 Tuesday, August 10, 2010 8:39 AM

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 fuel tank breather/overflow hose for obstructions, cracks or damage, and
check 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
U23PE1E0.book Page 1 Tuesday, August 10, 2010 8:39 AM

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 throttle grip free play.
 If necessary, have Yamaha dealer adjust throttle grip 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
U23PE1E0.book Page 2 Tuesday, August 10, 2010 8:39 AM

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. √√√√
U23PE1E0.book Page 4 Tuesday, August 10, 2010 8:39 AM

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
U23PE1E0.book Page 21 Tuesday, August 10, 2010 8:39 AM

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
U23PE1E0.book Page 22 Tuesday, August 10, 2010 8:39 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
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.
EAU23095
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
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711]
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
U23PE1E0.book Page 23 Tuesday, August 10, 2010 8:39 AM

INDEX
AABS ...................................................... 3-20
ABS warning light ................................... 3-7
Air filter element.................................... 6-16
Anti-theft alarm (optional) ..................... 3-15
Auxiliary DC jack .................................. 3-34
Auxiliary light bulb, replacing ................ 6-34BBattery .................................................. 6-28
Brake and clutch fluids, changing ......... 6-23
Brake and clutch levers, checking and lubricating ........................................... 6-25
Brake and shift pedals, checking and lubricating ........................................... 6-24
Brake fluid level, checking .................... 6-22
Brake lever ........................................... 3-18
Brake lever free play, checking ............ 6-20
Brake light switches .............................. 6-21
Brake pedal .......................................... 3-19CCables, checking and lubricating .......... 6-23
Care ........................................................ 7-1
Carriers ................................................. 3-31
Catalytic converter ................................ 3-24
Centerstand and sidestand, checking and lubricating .................................... 6-25
Clutch lever.................................. 3-17, 6-20
Coolant ................................................. 6-15
Coolant temperature warning light.......... 3-5
Cowlings, removing and installing .......... 6-8DDimmer switch ...................................... 3-16
D-mode (drive mode).............................. 3-1
EEngine break-in .......................................5-3
Engine idling speed, checking............... 6-17
Engine oil and oil filter cartridge ............ 6-11
Engine stop switch ................................ 3-16
Engine trouble warning light .................... 3-7FFinal gear oil.......................................... 6-14
Front and rear brake pads, checking .... 6-21
Front fork, adjusting .............................. 3-28
Front fork, checking...............................6-26
Fuel ....................................................... 3-23
Fuel consumption, tips for reducing ........ 5-3
Fuel tank breather/overflow hose .......... 3-24
Fuel tank cap......................................... 3-22
Fuses, replacing .................................... 6-29HHandlebar switches ............................... 3-16
Hazard switch........................................ 3-17
Headlight bulb, replacing....................... 6-31
High beam indicator light......................... 3-5
Horn switch ........................................... 3-16IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-32
Immobilizer system .................................3-1
Immobilizer system indicator light ........... 3-8
Indicator lights and warning lights ........... 3-4LLicense plate light bulb, replacing ......... 6-33
Luggage strap holders .......................... 3-31MMain switch/steering lock ........................ 3-3
Maintenance and lubrication, periodic..... 6-4 Maintenance, emission control system ... 6-3
Matte color, caution ................................ 7-1
Model label ............................................. 9-1
Multi-function meter unit ......................... 3-8
NNeutral indicator light .............................. 3-5OOil level warning light .............................. 3-5PParking.................................................... 5-4
Part locations .......................................... 2-1
Pass switch ........................................... 3-16RRider seat ............................................. 3-25
Rider seat height, adjusting .................. 3-26SSafety information ................................... 1-1
Shifting .................................................... 5-2
Shift pedal ............................................. 3-18
Shock absorber assembly, adjusting .... 3-29
Sidestand .............................................. 3-32
Spark plugs, checking........................... 6-10
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ........................................... 3-16
Steering, checking ................................ 6-27
Storage ................................................... 7-3
Swingarm pivots, lubricating ................. 6-26TTail/brake light ...................................... 6-32
Throttle grip and cable, checking and
lubricating ........................................... 6-24
Throttle grip free play, checking............ 6-17
Tires ...................................................... 6-18
U23PE1E0.book Page 1 Tuesday, August 10, 2010 8:39 AM