2019 YAMAHA XT1200ZE service

Instrument and control functions
3-39
3
TIP
The damping force setting can be set to
7 levels (+3, +2, +1, 0, –1, –2 and –3).
“+3” is the hardest level and “–3” is the
softest level.
6. Push the menu switch.
If the vehicle moves while you are ad-
justing the damping force, the informa-
tion display will change to the display
mode.
WARNING
EWA16421
The rear shock a bsor ber assem bly
contains hi ghly pressurize d nitro gen
g as. Rea d an d un derstan d the fol-
lowin g information before han dlin g
the shock a bsor ber assem bly.
 Do not tamper with or attempt
to open the cylind er assembly.
 Do not su bject the shock a b-
sor ber assem bly to an open
flame or other hi gh heat source.
This may cause the unit to ex-
plo de due to excessive g as
pressure. 
Do not deform or damag e the
cylin der in any way. Cylin der
d amag e will result in poor
d ampin g performance.
 Do not dispose of a dama ged or
worn-out shock a bsor ber
as-
sem bly yourself. Take the shock
a b sor ber assem bly to a Yamaha
d ealer for any service.
1. Damping force adjusting function
2. Damping force setting
3. Preload setting pictogram
GEAR
N
HARD
+3
GEAR
1
HARD+3
1
2
3
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Periodic maintenance an d a djustment
6-1
6
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to d
eath. See pag e 1-3 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot durin g
use. To avoi d possi ble burns, let
b rake components cool before
touching them.
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Periodic maintenance an d a djustment
6-2
6
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and equipped to perform these particular
services.
EAU85230
Tool kit
The tool kit is in the location shown.
The information included in this manual
and the tools provided in the tool kit are
intended to assist you in the perfor-
mance of preventive maintenance and
minor repairs. However, a torque
wrench and other tools are necessary
to perform certain maintenance work
correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
your Yamaha dealer perform it for you.
1. Tool kit
1. Hexagon wrench
1
1
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Periodic maintenance an d a djustment
6-6
6
EAU72841
TIP
Air filter
 This model’s air filter uses a disposable oil-coated paper element, which
must be replaced. Do not clean with compressed air, doing so will only dam-
age it.
 The air filter element needs to be replaced more frequently if you often ride in
the rain or dusty areas.
Hydraulic brake and clutch service  Regularly check the brake fluid and clutch fluid reservoirs. Replenish as nec-
essary.
 Every two years replace the internal components of the brake master cylin-
ders 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 or sooner if cracked or
damaged.
26 *Final gear oil • Check oil level and vehicle for
oil leakage. √√√√√
• Change. √√√
27 *Front an
d rear
b rake switches • Check operation.
√√√√√√
28 *Movin
g parts an d
cab les • Lubricate.
√√√√√
29 *Throttle
grip hous-
in g an d ca ble • Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous- ing, cable and grip warmer
wire. √√√√√
30 *Li
ghts, si gnals an d
switches • Check operation.
• Adjust headlight beam.
√√√√√√
NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi ODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
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Periodic maintenance an d a djustment
6-19
6
EAU21403
Valve clearance
The valves are an important engine
component, and since valve clearance
changes with use, they must be
checked and adjusted at the intervals
specified in the periodic maintenance
chart. Unadjusted valves can result in
improper air-fuel mixture, engine
noise, and eventually engine damage.
To prevent this from occurring, have
your Yamaha dealer check and adjust
the valve clearance at regular intervals.
TIP
This service must be performed when
the engine is cold.
EAU64412
Tires
Tires are the only contact between the
vehicle and the road. Safety in all con-
ditions of riding depends on a relatively
small area of road contact. Therefore, it
is essential to maintain the tires in good
condition at all times and replace them
at the appropriate time with the speci-
fied tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
WARNING
EWA10504
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or d eath from loss of
control.  The tire air pressure must b e
checked and a djuste d on col d
tires (i.e., when the temperature
of the tires equals the am bient
temperature).
 The tire air pressure must b e
a d juste d in accor dance with the
ri din g speed and with the total
wei ght of ri der, passen ger, car-
g o, an d accessories approve d
for this mo del.
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Periodic maintenance an d a djustment
6-23
6
EAU37914
Checkin g the brake lever free
play
There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14212
A soft or spon gy feelin g in the brake
lever can in dicate the presence of
air in the hy draulic system. If there is
air in the hy draulic system, have a
Yamaha dealer blee d the system be-
fore operatin g the vehicle. Air in the
hy draulic system will diminish the
b rakin g performance, which may re-
sult in loss of control an d an acci-
d ent.
EAU36505
Brake li ght switches
The brake light should come on just
before braking takes effect. The brake
light is activated by switches connect-
ed to the brake lever and brake pedal.
Since the brake light switches are
components of the anti-lock brake sys-
tem, they should only be serviced by a
Yamaha dealer.
1. No brake lever free play
1
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Periodic maintenance an d a djustment
6-39
6
EAU25872
Trou bleshootin g
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checkin g the fuel system, d o
not smoke, an d make sure there are
no open flames or sparks in the ar-
ea, inclu din g pilot li ghts from water
heaters or furnaces. Gasoline or
g asoline vapors can i gnite or ex-
plo de, causin g severe injury or prop-
erty damag e.
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Specifications
8-1
8
Dimensions:
Overall length:2250 mm (88.6 in)
Overall width:
980 mm (38.6 in)
Overall height: 1410/1470 mm (55.5/57.9 in)
Seat height: 845/870 mm (33.3/34.3 in)
Wheelbase:
1540 mm (60.6 in)
Ground clearance: 190 mm (7.48 in)
Minimum turning radius: 2.7 m (8.86 ft)
Wei ght:
Curb weight:
266 kg (586 lb)
Engine:
Combustion cycle:
4-stroke
Cooling system:
Liquid cooled
Valve train: DOHC
Cylinder arrangement: Inline
Number of cylinders:
2-cylinder
Displacement: 1199 cm³
Bore × stroke:
98.0 × 79.5 mm (3.86 × 3.13 in)
Starting system:
Electric starter
Engine oil:
Recommended brand:
SAE viscosity grades:
10W-40
Recommended engine oil grade: API service SG type or higher, JASO
standard MA
Engine oil quantity: Oil change: 3.10 L (3.28 US qt, 2.73 Imp.qt) With oil filter removal:
3.40 L (3.59 US qt, 2.99 Imp.qt)
Final gear oil:
Type:
Yamaha genuine shaft drive gear oil SAE 80W-90 API GL-5 or SAE 80 API GL-4
Hypoid gear oil
Quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt)
Coolant quantity:
Coolant reservoir (up to the maximum level
mark):
0.26 L (0.27 US qt, 0.23 Imp.qt)
Radiator (including all routes):
1.83 L (1.93 US qt, 1.61 Imp.qt)
Fuel:
Recommended fuel:Premium unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity: 23 L (6.1 US gal, 5.1 Imp.gal)
Fuel reserve amount:
3.9 L (1.03 US gal, 0.86 Imp.gal)
Fuel injection:
Throttle body:ID mark:BP81 00
Drivetrain:
Gear ratio:
1st: 2.769 (36/13)
2nd:
2.063 (33/16)
3rd: 1.571 (33/21)
4th: 1.250 (30/24)
5th:
1.042 (25/24)
6th: 0.929 (26/28)
Front tire:
Type:
Tubeless
Size: 110/80R19M/C 59V
Manufacturer/model: BRIDGESTONE/BW501
UBP9E1E0.book Page 1 Friday, September 7, 2018 10:01 AM