2013 YAMAHA XT1200Z checking oil

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
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator lights and warning lights ............................................3-4
Multi-function meter unit .................3-8
D-mode (drive mode) ....................3-15
Handlebar switches ......................3-16
Clutch lever ...................................3-18
Shift pedal .....................................3-18
Brake lever ...................................3-19
Brake pedal ..................................3-20
ABS ..............................................3-20
Traction control system ................3-21
Fuel tank cap ................................3-23
Fuel ...............................................3-23
Fuel tank breather hose and 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 ............................... 6-2
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 ........................................... 6-21
Brake light switches ..................... 6-21
Checking the front and rear brake
pads .......................................... 6-22
Checking the brake fluid level ...... 6-22
Changing the brake and clutch
fluids ......................................... 6-24
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 ....... 6-26
Lubricating the swingarm pivots ........................................ 6-26
Checking the front fork ................. 6-27
Checking the steering .................. 6-27U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM

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)
U23PE3E0.book Page 10 Monday, July 30, 2012 8:44 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
11. 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)
U23PE3E0.book Page 13 Monday, July 30, 2012 8:44 AM

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
2
3
1
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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
U23PE3E0.book Page 15 Monday, July 30, 2012 8:44 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6
EAU22752
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the periodic maintenance
and lubrication chart or in the TIP after
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake and clutch master cylin-
ders and calipers as well as the brake
and clutch hoses replaced at the inter-
vals listed below or whenever they are
damaged or leaking.●
Oil seals: Replace every two
years.
●
Brake and clutch hoses: Replace
every four years.
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 sh ift 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.
Brake pedal
Shift pedal
U23PE3E0.book Page 24 Monday, July 30, 2012 8:44 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
6
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.
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.
U23PE3E0.book Page 27 Monday, July 30, 2012 8:44 AM

INDEXAABS ....................................................... 3-20
ABS warning light.................................... 3-7
Air filter element .................................... 6-16
Auxiliary DC jack ................................... 3-35
Auxiliary light bulb, replacing ................ 6-34BBattery................................................... 6-28
Brake and clutch fluids, changing ......... 6-24
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 ............................................ 3-19
Brake lever free play, checking ............. 6-21
Brake light switches .............................. 6-21
Brake pedal ........................................... 3-20CCare ........................................................ 7-1
Carriers ................................................. 3-31
Catalytic converter ................................ 3-25
Centerstand and sidestand, checking
and lubricating .................................... 6-26
Clutch lever .................................. 3-18, 6-20
Coolant.................................................. 6-15
Coolant temperature warning light .......... 3-4
Cowlings, removing and installing........... 6-8DDimmer switch ...................................... 3-16
D-mode (drive mode) ............................ 3-15EEngine break-in ....................................... 5-3
Engine idling speed, checking .............. 6-17 Engine oil and oil filter cartridge ........... 6-11
Engine stop switch................................ 3-17
Engine trouble warning light ................... 3-7
FFinal gear oil ......................................... 6-14
Front and rear brake pads, checking .... 6-22
Front fork, adjusting .............................. 3-28
Front fork, checking .............................. 6-27
Fuel....................................................... 3-23
Fuel consumption, tips for reducing........ 5-3
Fuel tank breather hose and overflow
hose ................................................... 3-24
Fuel tank cap ........................................ 3-23
Fuses, replacing ................................... 6-29HHandlebar switches .............................. 3-16
Hazard switch ....................................... 3-17
Headlight bulb, replacing ...................... 6-31
High beam indicator light ........................ 3-4
Horn switch ........................................... 3-17IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-33
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 .......................... 3-32MMain switch/steering lock........................ 3-2
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 .............................. 3-4OOil level warning light .............................. 3-4PParking .................................................... 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 .... 3-30
Sidestand .............................................. 3-32
Spark plugs, checking ........................... 6-10
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch............................................ 3-17
Steering, checking................................. 6-27
Storage.................................................... 7-4
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
Tool kit..................................................... 6-2
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM