2015 YAMAHA XT1200ZE 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
Immobilizer system......................... 3-1
Main switch/steering lock............... 3-2
Indicator lights and warning lights............................................ 3-4
Cruise control system..................... 3-7
Multi-function meter unit .............. 3-10
D-mode (drive mode).................... 3-24
Handlebar switches ...................... 3-24
Clutch lever .................................. 3-26
Shift pedal .................................... 3-27
Brake lever.................................... 3-27
Brake pedal .................................. 3-28
ABS .............................................. 3-28
Traction control system ................ 3-29
Fuel tank cap ................................ 3-31
Fuel ............................................... 3-32
Fuel tank breather hose and
overflow hose ............................ 3-33
Catalytic converter ....................... 3-33
Rider seat ..................................... 3-34
Adjusting the rider seat height...... 3-35
Windshield .................................... 3-36 Adjusting the front and rear
suspension ................................ 3-37
Carriers.......................................... 3-42
Luggage strap holders .................. 3-42
Sidestand ...................................... 3-43
Ignition circuit cut-off system ....... 3-43
Auxiliary DC jack ........................... 3-45
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 ............................ 6-17
Checking the engine idling
speed ........................................ 6-17
Checking the throttle grip free
play ............................................ 6-17
Valve clearance............................. 6-18
Tires .............................................. 6-18
Spoke wheels ............................... 6-20
Clutch lever................................... 6-21
Checking the brake lever free play ............................................ 6-21
Brake light switches ..................... 6-22
Checking the front and rear brake pads .......................................... 6-22
Checking the brake fluid level ...... 6-23
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............... 6-25
Checking and lubricating the
brake and clutch levers ............. 6-25
Checking and lubricating the centerstand and sidestand........ 6-26
Lubricating the swingarm pivots......................................... 6-27
Checking the front fork ................. 6-27
Checking the steering................... 6-28
Checking the wheel bearings ....... 6-28U2KBE1E0.book Page 1 Monday, August 18, 2014 9:42 AM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15598
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
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an acci dent or equipment damag e.
Do not operate the vehicle if you fin d any pro blem. If a pro blem cannot be corrected b y the proce dures provi ded in
this manual, have the vehicle inspecte d b y 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 hose and overflow hose for obstructions, cracks or
damage, and check hose connections. 3-32, 3-33
En gine oil • Check oil level in engine.
• 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 specified brake fluid to specified level.
• Check hydraulic system for leakage. 6-22, 6-23
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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 specified brake fluid to specified level.
• Check hydraulic system for leakage. 6-22, 6-23
Clutch • Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check hydraulic system for leakage. 6-21
Throttle g rip • Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing. 6-17, 6-24
Wheels an d tires •Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary. 6-18, 6-20
Brake an d shift pe dals • Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-25
Brake an d clutch levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-25
Centerstan d, si destan d • Make sure that operation is smooth.
• Lubricate pivots if necessary. 6-26
Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, li ghts, si gnals
an d switches • Check operation.
• Correct if necessary.
—
Si destan d switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle. 3-43
ITEM
CHECKS PAGE
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770K
General maintenance and lu brication chartNO. ITEM CHECK OR MAINTENANCE JOB ODOMETER 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.
• Check for correct routing and
clamping. √√√√√
• Replace. Every 4 years
6 *Brake flui d • Replace. Every 2 years
7 *Wheels • Check rim runout and spokes for
damage.
• Tighten all spokes. At the initial 1000 km (600 mi) and every 5000 km (3000 mi) thereafter.
8 *Tires • Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√√√√
9 *Wheel bearin gs • Check bearings for looseness or
damage. √√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6
EAU22283
Brake light switchesThe brake light, which is activated by
the brake pedal and brake lever,
should come on just before braking
takes effect. Since the brake light
switches are components of the cruise
control system, they must be adjusted
by a Yamaha dealer, who has the nec-
essary professional knowledge and ex-
perience.
EAU22393
Checkin g the front an d rear
b rake pa dsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36891
Front brake pa ds
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 to
the point that a wear indicator almost touches the brake disc, have a
Yamaha dealer replace the brake pads as a set.
EAU22501
Rear brake pad s
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.
1. Brake pad wear indicator
1
1
1. Lining thickness
11
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU40262
Checking the brake flui d levelBefore riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake Rear
brake
WARNING
EWA16011
Improper maintenance can result in
loss of b raking a bility. O bserve
these precautions:  Insufficient brake flui d may al-
low air to enter the b rake sys-
tem, re ducin g brakin g
performance.
 Clean the filler cap before re-
movin g. Use only DOT 4 b rake
flui d from a seale d container. 
Use only the specifie d b rake flu-
i d ; otherwise, the ru bber seals
may deteriorate, causin g leak-
a g e.
 Refill with the same type of
brake flui d. A dding a brake flui d
other than DOT 4 may result in a
harmful chemical reaction.
 Be careful that water or dust
d oes not enter the brake flui d
reservoir when refilling . Water
will si gnificantly lower the boil-
in g point of the flui d an d may re-
sult in vapor lock, an d d ir
t may
clo g the ABS hy draulic unit
valves.
NOTICE
ECA17641
Brake flui d may damag e painte d
surfaces or plastic parts. Always
clean up spille d flui d imme diately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
1. Minimum level mark
LOWER
1
1. Minimum level mark
Specified b rake flui d:
DOT 4
1
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10-1
10
INDEX
AABS....................................................... 3-28
ABS warning light ................................... 3-5
Air filter element.................................... 6-17
Auxiliary DC jack .................................. 3-45
Auxiliary light bulb, replacing ............... 6-33BBattery .................................................. 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........................................... 6-25
Brake fluid level, checking.................... 6-23
Brake lever............................................ 3-27
Brake lever free play, checking ............ 6-21
Brake light switches ............................. 6-22
Brake pedal .......................................... 3-28CCare ........................................................ 7-1
Carriers ................................................. 3-42
Catalytic converter ............................... 3-33
Centerstand and sidestand, checking
and lubricating ................................... 6-26
Clutch lever.................................. 3-26, 6-21
Coolant ................................................. 6-15
Cowlings, removing and installing.......... 6-8
Cruise control indicator lights................. 3-4
Cruise control switches ........................ 3-25
Cruise control system............................. 3-7DDimmer/Pass switch............................. 3-25
D-mode (drive mode)............................ 3-24
EElectronically adjustable suspension system warning light ............................ 3-6
Engine break-in ...................................... 5-3
Engine idling speed, checking ............. 6-17
Engine oil and oil filter cartridge........... 6-11
Engine serial number ............................. 9-1
Engine trouble warning light .................. 3-5FFinal gear oil ......................................... 6-14
Front and rear brake pads, checking ... 6-22
Front fork, checking ............................. 6-27
Fuel ...................................................... 3-32
Fuel consumption, tips for reducing ...... 5-3
Fuel tank breather hose and overflow
hose ................................................... 3-33
Fuel tank cap........................................ 3-31
Fuses, replacing ................................... 6-30HHandlebar switches ............................. 3-24
Hazard switch ...................................... 3-25
Headlight bulb, replacing ..................... 6-31
High beam indicator light ....................... 3-4
Horn switch .......................................... 3-25IIdentification numbers ........................... 9-1
Ignition circuit cut-off system .............. 3-43
Immobilizer system ................................ 3-1
Immobilizer system indicator light ......... 3-6
Indicator lights and warning lights ......... 3-4LLicense plate light bulb, replacing ....... 6-35
Luggage strap holders ......................... 3-42
MMain switch/steering lock ....................... 3-2
Maintenance and lubrication, periodic ... 6-4
Maintenance, emission control
system .................................................. 6-3
Matte color, caution................................ 7-1
Menu switch ......................................... 3-25
Model label ............................................. 9-1
Multi-function meter unit ...................... 3-10NNeutral indicator light ............................. 3-4OOil level warning light .............................. 3-4PParking.................................................... 5-4
Part locations.......................................... 2-1RRider seat.............................................. 3-34
Rider seat height, adjusting .................. 3-35SSafety information................................... 1-1
Select switch ........................................ 3-26
Shifting.................................................... 5-2
Shift pedal............................................. 3-27
Sidestand.............................................. 3-43
Spark plugs, checking .......................... 6-10
Specifications ......................................... 8-1
Start/Engine stop switch ...................... 3-25
Starting the engine ................................. 5-1
Steering, checking ................................ 6-28
Storage ................................................... 7-4
Suspension, adjusting the front and
rear ..................................................... 3-37
Swingarm pivots, lubricating ................ 6-27
U2KBE1E0.book Page 1 Monday, August 18, 2014 9:42 AM