2013 YAMAHA XT1200Z engine

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

SAFETY INFORMATION
1-2
1
●
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license. Make sure that you are qualified and that you only lend your mo-
torcycle to other qualified opera-
tors.
Know your skills and limits. Staying within your limits may
help you to avoid an accident.
We recommend that you prac- tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
●
Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed). Always obey the speed limit and never travel faster than warrant-
ed by road and traffic conditions. Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
●
The posture of the operator and
passenger is important for proper
control. The operator should keep both hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
●
Never ride under the influence of
alcohol or other drugs.
Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
●
Always wear an approved helmet.
●
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
●
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
●
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
●
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM

SAFETY INFORMATION
1-3
1Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
●
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
●
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
●
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors. Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
When loading within this weight limit,
keep the following in mind:
●
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as close to the center of the vehicle as
possible and make sure to distrib-
ute the weight as evenly as possi-
ble on both sides of the motorcycle
to minimize imbalance or instabili-
ty.
●
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
Never attach any large or heavy items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
tents, can create unstable han-
dling or a slow steering re-
sponse.
●
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Maximum load: 209 kg (461 lb)
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SAFETY INFORMATION
1-4
1
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces- sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod- ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
●
Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle- bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum. Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
●
Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
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DESCRIPTION
2-1
2
EAU10410
Left view
132
76 54
10 9 8
1. Fuel tank cap (page 3-23)
2. Seat lock (page 3-25)
3. Carrier (page 3-31)
4. Final gear oil filler bolt (page 6-14)
5. Final gear oil drain bolt (page 6-14)
6. Coolant reservoir (page 6-15)
7. Shift pedal (page 3-18)
8. Engine oil drain bolt (oil tank) (page 6-11) 9. Engine oil drain bolt (crankcase) (page 6-11)
10.Engine oil filter cartridge (page 6-11)
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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 spri ng 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 6-2)
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 3-20)
14.Shock absorber assembly
rebound damping force adjusting knob
(page 3-30)U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
●
Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
EAU10472
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.TIPBe sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.
EAU26811
ON
All electrical circuits are supplied with
power; the meter lighting, taillights, li-
cense plate light and auxiliary lights
come on, and the engine can be start-
ed. The key cannot be removed.TIPThe headlights come on automatically
when the engine is started and stay on
until the key is turned to “OFF”.
EAU10661
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10061
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident.
EAU10692
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU49392
Indicator lights and warning
lights
EAU11030
Turn signal indicator lights “ ”
and “ ”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11254
Oil level warning light “ ”
This warning light comes on if the en-
gine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. The warning light should come
on for a few seconds, and then go off.
If the warning light does not come on
initially when the key is turned to “ON”,
or if the warning light remains on, have
a Yamaha dealer check the electrical
circuit.
TIP●
Even if the oil level is sufficient, the
warning light may flicker when
riding on a slope or during sudden
acceleration or deceleration, but
this is not a malfunction.
●
This model is also equipped with a
self-diagnosis device for the oil
level detection circuit. If a problem
is detected in the oil level detection
circuit, the following cycle will be
repeated until the malfunction is
corrected: The oil level warning
light will flash ten times, then go off
for 2.5 seconds. If this occurs,
have a Yamaha dealer check the
vehicle.
EAU49424
Coolant temperature warning
light “ ”
This warning light comes on if the en-
gine overheats. If this occurs, stop the
engine immediately and allow the en-
gine to cool.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. The warning light should come
on for a few seconds, and then go off.
1. Engine trouble warning light “ ”
2. Oil level warning light “ ”
3. Traction control system indicator/warning light “TCS”
4. Left turn signal indicator light “ ”
5. Anti-lock Brake System (ABS) warning light “ ”
6. High beam indicator light “ ”
7. Neutral indicator light “ ”
8. Coolant temperature warning light “ ”
9. Immobilizer system indicator light
10.Right turn signal indicator light “ ”
6
10
789
12345
ABS
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM