2015 YAMAHA XT1200ZE Owners Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU36773
TIPAir filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com- pressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
 Hydraulic brake and clutch service
• Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.
• Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders, and change the brake and clutch fluids.
• Replace the brake and clutch hoses every four years and if cracked or damaged.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
EAU18782
Removing an d installin g cowl-
in gsThe cowlings shown need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.
Refer to this section each time a cowl-
ing needs to be removed and installed.
EAU55960
Cowlin g A
To remove the cowlingRemove the quick fastener screws,
and then pull the cowling off as shown. To install the cowling
1. Fit the projections on the cowling
into the matching holes in cowling
B.
1. Cowling A
2. Cowling B
1
2
1. Cowling C
1
1. Cowling A
2. Quick fastener screw
1. Projection
2. Matching hole
3. Cowling B2
2
1
12
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6
2. Install the quick fastener screws.
Cowlin g B
To remove the cowling
1. Remove cowling A.
2. Remove the bolts and the quick fasteners, and then pull the cowl-
ing off.
To install the cowling
1. Place the cowling in the originalposition, and then install the bolts
and the quick fasteners.
2. Install cowling A.
Cowlin g C
To remove the cowlingRemove the bolts and the nuts, and
then take the cowling off.
1. Cowling B
2. Bolt
2
1
2
1. Quick fastener
1
1. Cowling C
2. Nut
3. Bolt
1. Cowling C
2. Nut
3. Bolt
2
3
1
1
2
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6To install the cowling
Place the cowling in the original posi-
tion, and then install the bolts and the
nuts.
EAU19653
Checkin
g the spark plu gsThe spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and depos- its will cause any spark plug to slowly
erode, they should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition of
the engine.
The porcelain insulator around the
center 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 engine should have the same
color. If any spark plug shows a dis-
tinctly different color, the engine could
be operating improperly. Do not at-
tempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of elec-
trode 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.
Specifie
d spark plu g:
NGK/CPR8EB91. Spark plug gapSpark plu g g ap:
0.8–0.9 mm (0.031–0.035 in)
Ti ghtenin g torque:
Spark plug: 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
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
specified torque as soon as possible.NOTICE
ECA10841
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the i gnition coil coupler may get
d amag ed . The spark plu g cap may
b e difficult to remove because the
ru bber seal on the en d of the cap fits
ti g htly. To remove the spark plu g
cap, simply twist it back an d forth
while pullin g it out; to install it, twist
it back an d forth while pushin g it in.
EAU49504
En gine oil an d oil filter car-
tri dgeThe 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 en gine oil level
1. 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 chan ge the en gine oil (with or
without oil filter cartri dge 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.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
42
3
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
64. 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.
TIPSkip steps 7–11 if the oil filter cartridge
is not being replaced.7. Remove cowling C. (See page6-8.)
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.
1. Engine oil drain bolt (oil tank)
2. Gasket
12
1. Engine oil drain bolt (crankcase)
2. Gasket
12
1. Oil filter cartridge
2. Oil filter wrench21
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
TIPMake sure that the O-ring is properly
seated.10. Install the new oil filter cartridgewith an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench. 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
ECA11621
In or der to prevent clutch slip-
pa ge (since the en gine oil also
lu bricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a hi gh-
er quality than specifie d. In
1. O-ring
1. Torque wrench
Ti ghtenin g torque:
Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)
Ti ghtenin g 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
Recommen ded en gine 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)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6a
ddition, do not use oils la beled
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn 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,
immediately 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
ECA10402
If the oil level warnin g lig ht flickers
or remains on even if the oil level is
correct, imme diately turn the en gine
off an d have a Yamaha d ealer check
the vehicle.15. Turn the engine off, wait a few minutes until the oil settles, and
then check the oil level and cor-
rect it if necessary.
EAU20017
Final g ear oilThe 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 ad-
dition, the final gear oil level must be
checked and the oil changed as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
WARNING
EWA10371
Make sure that no forei gn mate-
rial enters the final g ear case.
 Make sure that no oil gets on
the tire or wheel.To check the final gear oil level
1. Place the vehicle on the center- stand.TIPMake sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult 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 thefiller hole, add sufficient oil of the
recommended 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.1. Final gear oil filler bolt
2. Gasket
3. Correct oil level
1
2
3
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