2012 YAMAHA XT1200Z engine

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 gap
Spark 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)
U23PE2E0.book Page 10 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
EAU49503
Engine oil and oil filter car-
tridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level1. Place the vehicle on the center- stand. A slight tilt to the side can
result in a false reading.
2. Start the engine and warm it up for ten minutes until the engine oil has
reached a normal temperature of
60 °C (140 ° F), and then turn the
engine off.
3. Wait a few minutes until the oil set- tles, and then check the oil level
through the engine oil level check
window located at the bottom-right
side of the crankcase.TIPThe engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter cartridge replace-
ment) 1. Place the vehicle on a level sur- face.
2. Start the engine, warm it up for several minutes, and then turn it
off.
3. Place an oil pan under the oil tank to collect the used oil. 4. Remove the engine oil filler cap,
the drain bolt and its gasket to
drain the oil from the oil tank.
5. Place an oil pan under the engine to collect the used oil.
6. Remove the engine oil drain bolt and its gasket to drain the oil from
the crankcase.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
42
3
1
1. Engine oil drain bolt (oil tank)
2. Gasket
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPSkip steps 7–11 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 engineoil 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. Oil filter cartridge
2. Oil filter wrench21
1. O-ring
U23PE2E0.book Page 12 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
611. Install the cowling.
12. Install the engine oil drain bolts
and their new gasket, and then
tighten the bolts to the specified
torques. 13. 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.
14. 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.15. Turn the engine off, wait a few min-utes until the oil settles, and then
check the oil level and correct it if
necessary.
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)
U23PE2E0.book Page 13 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
65. 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
6
4. 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)
U23PE2E0.book Page 16 Monday, August 1, 2011 4:25 PM

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.
EAU21384
Checking the throttle grip free
play The throttle grip 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 grip 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 grip free play
1
U23PE2E0.book Page 17 Monday, August 1, 2011 4:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6
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] EAU23114
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.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from water
entry. Therefore, use care not to pour
water directly onto the cover or cable
when washing the vehicle. If the cable
or cover becomes dirty, wipe clean with
a moist cloth.
EAU44273
Checking and lubricating the
brake and shift pedals 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:
Yamaha Chain and Cable Lube or
engine oil
U23PE2E0.book Page 24 Monday, August 1, 2011 4:25 PM