2019 YAMAHA XT1200ZE brake pads

Table of contents
Safety information ............................1-1
Description ........................................2-1
Left view ..........................................2-1
Right view........................................2-2
Controls and instruments ................2-3
Instrument an d control functions ....3-1
Immobilizer system .........................3-1
Main switch/steering lock ...............3-2
Indicator lights and warning lights ............................................3-3
Cruise control system .....................3-6
Multi-function meter unit .................3-9
D-mode (drive mode) ....................3-21
Handlebar switches.......................3-22
Clutch lever ...................................3-23
Shift pedal .....................................3-24
Brake lever ....................................3-24
Brake pedal ...................................3-25
ABS ...............................................3-26
Traction control system.................3-27
Fuel tank cap.................................3-29
Fuel................................................3-29
Fuel tank overflow hose ................3-31
Catalytic converter ........................3-31
Rider seat ......................................3-32
Adjusting the rider seat height ......3-33
Windshield.....................................3-34
Adjusting the front and rear suspension.................................3-35
Carriers..........................................3-40
Luggage strap holders ..................3-41
Auxiliary DC jack ...........................3-41
Sidestand ......................................3-42
Ignition circuit cut-off system........3-43
For your safety – pre-operation
checks ...............................................4-1
Operation an d important ri din g
points .................................................5-1
Starting the engine ..........................5-2
Shifting ............................................5-3
Tips for reducing fuel consumption ................................5-4 Engine break-in ............................... 5-5
Parking ............................................ 5-6
Perio dic maintenance an d
a d justment ........................................ 6-1
Tool kit ............................................ 6-2
Periodic maintenance charts .......... 6-3
Periodic maintenance chart for the emission control system.............. 6-3
General maintenance and lubrication chart........................... 6-4
Removing and installing cowlings ...................................... 6-7
Checking the spark plugs ............... 6-9
Canister......................................... 6-10
Engine oil ...................................... 6-10
Why Yamalube .............................. 6-13
Final gear oil.................................. 6-14
Coolant ......................................... 6-16
Air filter element ............................ 6-17
Checking the engine idling
speed......................................... 6-18
Checking the throttle grip free
play ............................................ 6-18
Valve clearance ............................. 6-19
Tires .............................................. 6-19
Spoke wheels ............................... 6-22
Clutch lever ................................... 6-22
Checking the brake lever free play ............................................ 6-23
Brake light switches ...................... 6-23
Checking the front and rear brake pads................................. 6-24
Checking the brake fluid level....... 6-25
Changing the brake and clutch fluids .......................................... 6-26
Checking and lubricating the throttle grip and cable ............... 6-26
Checking and lubricating the brake and shift pedals ............... 6-27
Checking and lubricating the
brake and clutch levers ............. 6-27
Checking and lubricating the centerstand and sidestand ........ 6-28
Lubricating the swingarm pivots... 6-28
Checking the front fork ................. 6-29
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For your safety – pre-operation checks
4-1
4
EAU63441
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating 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 d amage. Do not operate the vehicle if you fin d
any prob lem. 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 d ealer.
Before using this vehicle, check the following points:
ITEM CHECKSPAGE
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 con-
nections. 3-29,
3-31
En gine oil • Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage. 6-10
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. 6-16
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. 6-24,
6-25
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. 6-24,
6-25
Clutch • Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic
system.
• Check hydraulic system for leakage. 6-22
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Periodic maintenance an d a djustment
6-4
6
EAU71372
General maintenance an d lu brication chart
NO. ITEM
1 *Dia
gnostic system
check • Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes. √√√√√√
2 *Air filter element • Replace. Every 40000 km (24000 mi)
3 *Clutch • Check operation, fluid level and
vehicle for fluid leakage. √√√√√
4 *Front brake • Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces- sary. √√√√√√
5 *Rear brake • Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces- sary. √√√√√√
6 *Brake hoses • Check for cracks or damage.
√√√√√
• Replace. Every 4 years
7 *Brake flui d • Change. Every 2 years
8 *Wheels • Check runout and for damage.
• Tighten all spokes. At the initial interval and every
5000 km (3000 mi) thereafter
9 *Tires • Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√√√√
10 *Wheel bearin gs • Check bearing for looseness or
damage. √√√√
11 *Swin
garm pivot
b earin gs • Check operation and for exces-
sive play. √√√√
• Lubricate with lithium-soap- based grease. Every 50000 km (30000 mi)
12 *Steerin g b earin gs • Check bearing assemblies for
looseness. √√√√√
•

Moderately repack with lithium-
soap-based grease. Every 50000 km (30000 mi)
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi ODOMETER
READINGSANNUAL CHECK
1 10203040
0.6 6 12 18 24
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Periodic maintenance an d a djustment
6-24
6
EAU22393
Checkin g the front an d rear
b rake pa ds
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36891Front 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.
EAU22501Rear brake pa ds
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
11
1. Lining thickness
11
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Periodic maintenance an d a djustment
6-25
6
EAU40262
Checkin g the brake flui d level
Before 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 brakin g a bility. O bserve
these precautions:  Insufficient brake flui d may al-
low air to enter the brake sys-
tem, re ducing brakin g
performance. 
Clean the filler cap before re-
moving . 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 ddin g 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 d amage 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
fluid level goes down suddenly, have a
Yamaha dealer check the cause before further riding.
1. Minimum level mark
1. Minimum level mark
Specified b rake flui d:
DOT 4
LO WER1
1
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10-1
10
Index
A
ABS ....................................................... 3-26
ABS warning light ................................... 3-4
Air filter element .................................... 6-17
Auxiliary DC jack ................................... 3-41
Auxiliary light bulb, replacing ................ 6-35
B
Battery .................................................. 6-30
Brake and clutch fluids, changing ........ 6-26
Brake and clutch levers, checking
and lubricating .................................... 6-27
Brake and shift pedals, checking and
lubricating ........................................... 6-27
Brake fluid level, checking .................... 6-25
Brake lever ............................................ 3-24
Brake lever free play, checking............. 6-23
Brake light switches.............................. 6-23
Brake pedal........................................... 3-25
C
Canister................................................. 6-10
Care ........................................................ 7-1
Carriers ................................................. 3-40
Catalytic converter ................................ 3-31
Centerstand and sidestand, checking and lubricating .................................... 6-28
Clutch lever ................................. 3-23, 6-22
Coolant ................................................. 6-16
Cowlings, removing and installing .......... 6-7
Cruise control indicator lights ................. 3-4
Cruise control switches ........................ 3-23
Cruise control system ............................. 3-6
D
Data recording, vehicle ........................... 9-3
Diagnostic connector.............................. 9-2
Dimmer/Pass switch ............................. 3-22
D-mode (drive mode) ............................ 3-21
E
Engine break-in....................................... 5-5
Engine idling speed, checking .............. 6-18
Engine oil .............................................. 6-10
Engine serial number .............................. 9-1
Engine trouble warning light ................... 3-4
F
Final gear oil.......................................... 6-14
Front and rear brake pads, checking.... 6-24
Front fork, checking .............................. 6-29
Fuel ....................................................... 3-29
Fuel consumption, tips for reducing ....... 5-4
Fuel tank cap ........................................ 3-29
Fuel tank overflow hose ........................ 3-31 Fuses, replacing ................................... 6-32
H
Handlebar switches .............................. 3-22
Hazard switch....................................... 3-22
Headlight bulb, replacing ..................... 6-33
High beam indicator light ....................... 3-3
Horn switch .......................................... 3-22
I
Identification numbers ............................ 9-1
Ignition circuit cut-off system............... 3-43
Immobilizer system ................................ 3-1
Immobilizer system indicator light.......... 3-5
Indicator lights and warning lights ......... 3-3
L
License plate light bulb, replacing........ 6-38
Luggage strap holders ......................... 3-41
M
Main switch/steering lock....................... 3-2
Maintenance and lubrication, periodic ... 6-4
Maintenance, emission control
system.................................................. 6-3
Matte color, caution ............................... 7-1
Menu switch ......................................... 3-23
Model label ............................................. 9-1
Multi-function meter unit ........................ 3-9
N
Neutral indicator light ............................. 3-3
O
Oil level warning light ............................. 3-4
P
Parking ................................................... 5-6
Part locations ......................................... 2-1
R
Rider seat ............................................. 3-32
Rider seat height, adjusting.................. 3-33
S
Safety information .................................. 1-1
Select switch ........................................ 3-23
Shifting ................................................... 5-3
Shift pedal ............................................ 3-24
Sidestand ............................................. 3-42
Spark plugs, checking ............................ 6-9
Specifications ......................................... 8-1
Starting the engine ................................. 5-2
Steering, checking................................ 6-29
Stop/Run/Start switch .......................... 3-22
Storage ................................................... 7-4
Suspension, adjusting the front and rear ..................................................... 3-35
Suspension system warning light........... 3-5
UBP9E1E0.book Page 1 Friday, September 7, 2018 10:01 AM