Read this manual carefully before operating this vehicle.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM EAU50920 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. YAMAHA MOTOR ELECTRONICS CO., LTD. 1450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan DECLARATION of CONFORMITY We Company: YAMAHA MOTOR ELECTRONICS CO., LTD.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM INTRODUCTION EAU10102 Welcome to the Yamaha world of motorcycling! As the owner of the XT1200Z, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT1200Z.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM IMPORTANT MANUAL INFORMATION EAU10133 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM IMPORTANT MANUAL INFORMATION EAU10200 XT1200Z OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, July 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM TABLE OF CONTENTS SAFETY 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 ................
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM TABLE OF CONTENTS Checking the wheel bearings .......6-28 Battery ..........................................6-28 Replacing the fuses ......................6-29 Replacing a headlight bulb ...........6-31 Tail/brake light ..............................6-32 Replacing a turn signal light bulb ...........................................6-33 Replacing a license plate light bulb ...........................................6-33 Replacing an auxiliary light bulb ...
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM SAFETY INFORMATION EAU1031B 1 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM SAFETY INFORMATION ● ● Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. • Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. • Know your skills and limits. Staying within your limits may help you to avoid an accident.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM SAFETY INFORMATION 1 Carbon Monoxide is a colorless, odorless, 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.
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM SAFETY INFORMATION Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision. Genuine Yamaha accessories, which are available 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 accessories or offer other modifications for Yamaha vehicles.
U23PE3E0.book Page 5 Monday, July 30, 2012 8:44 AM SAFETY INFORMATION 1 Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to page 6-18 for tire specifications and more information on replacing your tires.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM DESCRIPTION EAU10410 Left view 1 2 3 2 10 1. 2. 3. 4. 5. 6. 7. 8. 9 8 Fuel tank cap (page 3-23) Seat lock (page 3-25) Carrier (page 3-31) Final gear oil filler bolt (page 6-14) Final gear oil drain bolt (page 6-14) Coolant reservoir (page 6-15) Shift pedal (page 3-18) Engine oil drain bolt (oil tank) (page 6-11) 7 6 54 9. Engine oil drain bolt (crankcase) (page 6-11) 10.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM DESCRIPTION EAU10420 Right view 1 2 3 4 2 5 6 7 14 1. 2. 3. 4. 5. 6. 7. 8. 13 12 11 10 9 Rear brake fluid reservoir (page 6-22) Shock absorber assembly spring preload adjusting knob (page 3-30) Front fork rebound damping force adjusting screw (page 3-28) Front fork spring preload adjusting bolt (page 3-28) Main fuse (page 6-29) ABS motor fuse (page 6-29) Fuse box (page 6-29) Front fork compression damping force adjusting screw (page 3-28) 8 9.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 2 10 1. 2. 3. 4. 5. 6. 7. 8. Clutch lever (page 3-18) Left handlebar switches (page 3-16) Clutch fluid reservoir (page 6-24) Multi-function meter unit (page 3-8) Auxiliary DC jack (page 3-35) Front brake fluid reservoir (page 6-22) Right handlebar switches (page 3-16) Brake lever (page 3-19) 9 9. Throttle grip (page 6-17) 10.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10977 Immobilizer system 3 1. Code re-registering key (red bow) 2. Standard keys (black bow) This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS ● Keep other immobilizer system keys away from the main switch as they may cause signal interference. EAU10472 Main switch/steering lock EAU26811 ON All electrical circuits are supplied with power; the meter lighting, taillights, license plate light and auxiliary lights come on, and the engine can be started. The key cannot be removed.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS To lock the steering 1 To unlock the steering 2 1 ECA11020 NOTICE 2 Do not use the parking position for an extended length of time, otherwise the battery may discharge. 3 1. Push. 2. Turn. 1. Turn the handlebars all the way to the left or right. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. 1. Push. 2. Turn.
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU49392 Indicator lights and warning lights 6789 10 5 4 3 2 1 EAU11030 Turn signal indicator lights “ ” and “ ” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. TIP EAU11060 ● Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EAU11080 1. Engine trouble warning light “ ” 2. Oil level warning light “ ” 3.
U23PE3E0.book Page 5 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS 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. ECA10021 NOTICE 3 Do not continue to operate the engine if it is overheating. TIP ● ● For radiator-fan-equipped vehicles, the radiator fan(s) automatically switch on or off according to the coolant temperature in the radiator.
U23PE3E0.book Page 6 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS Display Conditions What to do Under 39 °C (Under 103 °F) Message “Lo” is displayed. OK. Go ahead with riding. 40–116 °C (104–242 °F) Coolant temperature is displayed. OK. Go ahead with riding. 117–120 °C (243–249 °F) Message “HI” flashes. Stop the vehicle and allow it to idle until the coolant temperature goes down. Message “HI” flashes. Warning light comes on. Stop the engine and allow it to cool.
U23PE3E0.book Page 7 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11534 3 Engine trouble warning light “ ” This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the self-diagnosis system. (See page 3-14 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”.
U23PE3E0.book Page 8 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 1. Traction control system switch 2. Traction control system indicator/warning light “TCS” 3. Engine trouble warning light “ ” 4. Traction control system mode display Try to reset the traction control system and the lights by following the procedures under “Resetting” on page 3-22.
U23PE3E0.book Page 9 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS settings while riding can distract the operator and increase the risk of an accident.
U23PE3E0.book Page 10 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS Odometer and tripmeter modes the display between the various tripmeter and odometer modes in the following order: TRIP F → ODO → TRIP 1 → TRIP 2 → TRIP F 1 2 1. Odometer/tripmeter/fuel reserve tripmeter 2.
U23PE3E0.book Page 11 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS 3. Push the left button; the minute digits start flashing. 4. Push the right button to set the minutes. 5. Push the left button; the clock starts after the button is released. 3 Fuel meter TIP This fuel meter is equipped with a selfdiagnosis system. If a problem is detected in the electrical circuit, all display segments start flashing. If this occurs, have a Yamaha dealer check the electrical circuit.
U23PE3E0.book Page 12 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS AVE_ _._ km/L, AVE_ _._ L/100 km or AVE_ _._ MPG → air intake temperature Coolant temperature mode Instantaneous fuel consumption mode 1 1 Air intake temperature mode 1 3 2 1. Coolant temperature display The coolant temperature display indicates the temperature of the coolant. ECA10021 NOTICE 1.
U23PE3E0.book Page 13 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS To switch between the instantaneous fuel consumption displays, push the right button when one of the displays is shown. 3 TIP The instantaneous fuel consumption displays when the vehicle speed reaches 20 km/h (12 mi/h). Average fuel consumption mode 1 2 1. Average fuel consumption display 2. Right set button The average fuel consumption display modes “AVE_ _._ km/L”, “AVE_ _._ L/100 km” or “AVE_ _.
U23PE3E0.book Page 14 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS Traction control system mode display Self-diagnosis device TIP If the display indicates immobilizer system circuit error code 52, this could be caused by transponder interference. If this error code appears, try following the procedure below. 1. Use the code re-registering key to start the engine. 1 1 1.
U23PE3E0.book Page 15 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS ECA11590 NOTICE If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. 3 LCD and tachometer brightness control mode 1 2 3 4 To set the brightness 1. Turn the key to “OFF”. 2. Push and hold the left button. 3. Turn the key to “ON”, and then release the left button after five seconds. 4. Push the right button to select the desired brightness level. 5.
U23PE3E0.book Page 16 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS Touring mode “T” The touring mode “T” is suitable for various riding conditions. This mode allows the rider to enjoy smooth drivability from the low-speed range to the high-speed range. EAU1234B Handlebar switches Right 1 Left 1 2 Sports mode “S” This mode offers a sportier engine response in the low- to mid-speed range compared to the touring mode. 2 3 3 54 1. 2. 3. 4. 5.
U23PE3E0.book Page 17 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU12500 Horn switch “ ” Press this switch to sound the horn. 3 EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
U23PE3E0.book Page 18 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12830 Clutch lever 1 4 1 1. 2. 3. 4. EAU12871 Shift pedal 4 2 2 Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the clutch lever. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-33.
U23PE3E0.book Page 19 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS ● ● Resistance and vibration may be felt in the brake pedal while the front brake is being applied and the unified brake system is enabled, but this does not indicate a malfunction. The unified brake system does not function until the vehicle starts moving. The brake lever is equipped with a brake lever position adjusting dial.
U23PE3E0.book Page 20 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU49481 Brake pedal EAU54530 TIP ABS 1 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. TIP Resistance and vibration may be felt in the brake pedal while the front brake is being applied and the unified brake system is enabled, but this does not indicate a malfunction.
U23PE3E0.book Page 21 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS in the wheel hubs may be damaged, resulting in improper performance of the ABS and the unified brake system. 1 3 1. Front wheel hub 1 EAU49416 Traction control system The traction control system helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads.
U23PE3E0.book Page 22 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS TIP Use “TCS” mode “Off” to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. system off. Push the switch again to return to the previously selected mode “1” or “2”. ECA16800 NOTICE Use only the specified tires. (See page 6-18.) Using different sized tires will prevent the traction control system from controlling tire rotation accurately.
U23PE3E0.book Page 23 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13074 EAU13221 TIP The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel tank cap 1 EWA11091 2 3 WARNING Make sure that the fuel tank cap is properly closed after filling fuel. Leaking fuel is a fire hazard. 1. Unlock. 2. Fuel tank cap lock cover Fuel Make sure there is sufficient gasoline in the tank.
U23PE3E0.book Page 24 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS 1 ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. 2 EAU51150 Fuel tank breather hose and overflow hose EAU49461 1. Fuel tank filler tube 2. Maximum fuel level 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.
U23PE3E0.book Page 25 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13433 EAU49443 NOTICE Rider seat This model is equipped with a catalytic converter in the exhaust system. Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. To remove the rider seat 1. Insert the key into the seat lock, and then turn it counterclockwise. EWA10862 WARNING 3 ECA10701 Catalytic converter The exhaust system is hot after operation.
U23PE3E0.book Page 26 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU49474 Adjusting the rider seat height 1 2 1 2 3 1. Projection 2. Seat holder 1. Rider seat height position adjuster 3. Install the rider seat height position adjuster so that the match mark is aligned with the “L” mark as shown. 2. Remove the key. TIP ● ● Make sure that the rider seat is properly secured before riding. The rider seat height can be adjusted to change the riding position.
U23PE3E0.book Page 27 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS 4. Insert the projection on the rear of the rider seat into seat holder A as shown. 4. Insert the projection on the rear of the rider seat into seat holder B as shown. 1 1 1 2 2 3 1. Rider seat height position adjuster 1. Projection 2. Seat holder A (for low position) To change the rider seat height to the high position 1. Remove the rider seat. (See page 3-25.) 2.
U23PE3E0.book Page 28 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU49882 Windshield If the original windshield is removed and then reinstalled, be sure to install the windshield screws in the lower holes and tighten the screws to the specified torque. WARNING! A loose windshield could cause an accident. Be sure to tighten the screws to the specified torque. [EWA15510] EAU14743 TIP An accessory windshield is available at your Yamaha dealer.
U23PE3E0.book Page 29 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS 1 (a) (b) 3 1. Spring preload adjusting bolt Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt. Spring preload setting: Minimum (soft): 8 Standard: 5.5 Maximum (hard): 0 Rebound damping force To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw on each fork leg in direction (a).
U23PE3E0.
U23PE3E0.book Page 31 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EWA10221 (b) (a) 3 1 1. Rebound damping force adjusting knob Rebound damping setting: Minimum (soft): 20 clicks in direction (b)* Standard: 10 clicks in direction (b)* Maximum (hard): 3 clicks in direction (b)* * With the adjusting knob fully turned in direction (a) TIP To obtain a precise adjustment, it is advisable to check the actual total number of clicks or turns of each damping force adjusting mechanism.
U23PE3E0.book Page 32 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS Additional carrier EAU49490 Luggage strap holders 1 The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. 1 1. Additional carrier EWA15481 WARNING ● ● ● ● EAU15305 Sidestand Do not exceed the maximum load of 209 kg (461 lb) for the vehicle. Do not sit on and never ride with a passenger on the standard or additional carrier.
U23PE3E0.book Page 33 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS this system regularly and have a Yamaha dealer repair it if it does not function properly. 3 EAU44902 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U23PE3E0.book Page 34 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? WARNING • The vehicle must be placed on the center- ”. stand during this inspection. • If a malfunction is noted, have a Yamaha dealer check the system before riding.
U23PE3E0.book Page 35 Monday, July 30, 2012 8:44 AM INSTRUMENT AND CONTROL FUNCTIONS EAU49452 Auxiliary DC jack 1 EWA14360 WARNING To prevent electrical shock or shortcircuiting, make sure that the cap is installed when the auxiliary DC jack is not being used. 3 ECA15431 NOTICE The accessory connected to the auxiliary DC jack should not be used with the engine turned off, and the load must never exceed 30 W (2.5 A), otherwise the fuse may blow or the battery may discharge.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 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. EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS Rear brake • • • • • • • Clutch • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check hydraulic system for leakage. Throttle grip • Make sure that operation is smooth. • Check throttle grip free play. • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM OPERATION AND IMPORTANT RIDING POINTS EAU15951 EAU48710 EAU54520 Starting the engine Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM OPERATION AND IMPORTANT RIDING POINTS ECA17670 NOTICE If the above warning lights or indicator light do not come on initially when the key is turned to “ON”, or if a warning or indicator light remains on, see page 3-4 for the corresponding warning and indicator light circuit check. 5 The ABS warning light should come on when the main switch is turned to “ON” and then go off after traveling at a speed of 10 km/h (6 mi/h) or higher.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM OPERATION AND IMPORTANT RIDING POINTS ECA10260 NOTICE ● ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM OPERATION AND IMPORTANT RIDING POINTS 1000–1600 km (600–1000 mi) Avoid prolonged operation above 4700 r/min. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. ECA10310 EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10311 WARNING ● NOTICE ● ● 5 Keep the engine speed out of the tachometer red zone.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 EWA15122 EAU17302 WARNING 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 important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU49561 Owner’s tool kit 1 1. Owner’s tool kit 6 The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU46861 TIP ● ● ● The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a mileage-based maintenance, is performed instead. From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU1770F General maintenance and lubrication chart ODOMETER READING NO. ITEM CHECK OR MAINTENANCE JOB 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) ANNUAL CHECK √ 1 * Air filter element • Replace. 2 * Clutch • Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ • Check operation, fluid level and vehicle for fluid leakage.
U23PE3E0.book Page 5 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. ITEM 10 * Swingarm 11 * Steering bearings 12 * Chassis fasteners CHECK OR MAINTENANCE JOB 1000 km (600 mi) • Check operation and for excessive play. 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) √ √ √ √ • Lubricate with lithium-soap-based grease. • Check bearing play and steering for roughness.
U23PE3E0.book Page 6 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. ITEM 21 * Rear suspension relay arm and connecting arm pivoting points • Check operation. 22 Engine oil • Change. • Check oil level and vehicle for oil leakage. √ 23 Engine oil filter cartridge • Replace. √ 24 * Cooling system CHECK OR MAINTENANCE JOB 1000 km (600 mi) • Check coolant level and vehicle for coolant leakage.
U23PE3E0.book Page 7 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU36771 TIP ● ● Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed 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.
U23PE3E0.book Page 8 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT To install the cowling 1. Fit the projections on the cowling into the matching holes in cowling B. EAU18781 Removing and installing cowlings The cowlings shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling needs to be removed and installed. 1 2 3 1 1 2 1.
U23PE3E0.book Page 9 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU49550 2 1 Cowling C 1 To remove the cowling Remove the bolts and the nuts, and then take the cowling off. 2 2 3 1. Cowling B 2. Bolt 3 2 1. Cowling C 2. Nut 3. Bolt 1 To install the cowling Place the cowling in the original position, and then install the bolts and the nuts. 1. Cowling C 2. Nut 3. Bolt 1 1. Quick fastener To install the cowling 1.
U23PE3E0.book Page 10 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19652 Checking the spark plugs 6 The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
U23PE3E0.book Page 11 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the engine oil filler cap, the drain bolt and its gasket to drain the oil from the oil tank. EAU49503 Engine oil and oil filter cartridge 4 The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1.
U23PE3E0.book Page 12 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1 2 2 1 6 1. Engine oil drain bolt (crankcase) 2. Gasket 1. Oil filter cartridge 2. Oil filter wrench 1. O-ring TIP Skip steps 7–11 if the oil filter cartridge is not being replaced. TIP An oil filter wrench is available at a Yamaha dealer. 7. Remove cowling C. (See page 6-8.) 8. Remove the oil filter cartridge with an oil filter wrench. 9.
U23PE3E0.book Page 13 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 13. Refill with the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 1 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) 11. Install the cowling. 12. Install the engine oil drain bolts and their new gasket, and then tighten the bolts to the specified torques. Recommended engine oil: See page 8-1.
U23PE3E0.book Page 14 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU20016 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the vehicle. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. TIP The oil level should be at the brim of the filler hole.
U23PE3E0.book Page 15 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU20070 Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 5. Refill with the recommended final gear oil to the brim of the filler hole. Recommended final gear oil: Yamaha genuine shaft drive gear oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt) Coolant The coolant level should be checked before each ride.
U23PE3E0.book Page 16 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 6 4. Add coolant or distilled water to raise the coolant to the maximum level mark, install the coolant reservoir cap. WARNING! Remove only the coolant reservoir cap. Never attempt to remove the radiator cap when the engine is hot. [EWA15161] NOTICE: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.
U23PE3E0.book Page 17 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU44734 Checking the engine idling speed EAU21384 Checking the throttle grip free play Check the engine idling speed and, if necessary, have it corrected by a Yamaha dealer. Engine idling speed: 1050–1150 r/min 1 EAU21401 Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise.
U23PE3E0.book Page 18 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU49675 Tires Tires are the only contact between the vehicle and the road. Safety in all conditions 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 specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride.
U23PE3E0.book Page 19 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EWA10471 Tire information EWA10901 WARNING ● ● ● Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the vehicle with excessively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheel and brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience to do so.
U23PE3E0.
U23PE3E0.book Page 21 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU37913 Checking the brake lever free play braking performance, which may result in loss of control and an accident. 1 EAU36503 Brake light switches The brake light, which is activated by the brake pedal and brake lever, should come on just before braking takes effect. If necessary, have a Yamaha dealer adjust the brake light switches. 1.
U23PE3E0.book Page 22 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT Checking the front and rear brake pads the point that a wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
U23PE3E0.book Page 23 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● Rear brake ● UPPER 1 LOWER ● 1. Minimum level mark Specified brake fluid: DOT 4 EWA16010 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions: ● Insufficient brake fluid may allow air to enter the brake system, reducing braking performance. ● Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed container.
U23PE3E0.book Page 24 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22752 6 EAU23114 EAU44273 Changing the brake and clutch fluids Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals Have a Yamaha dealer change the brake and clutch fluids at the intervals specified in the periodic maintenance and lubrication chart or in the TIP after the periodic maintenance and lubrication chart.
U23PE3E0.book Page 25 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU43601 Recommended lubricant: Lithium-soap-based grease Checking and lubricating the brake and clutch levers Recommended lubricant: Silicone grease The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U23PE3E0.book Page 26 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23213 Checking and lubricating the centerstand and sidestand 6 EAUM1652 Recommended lubricant: Lithium-soap-based grease The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
U23PE3E0.book Page 27 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 EAU45511 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
U23PE3E0.book Page 28 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 Checking the wheel bearings EAU34225 Battery 1 2 3 6 The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Positive battery lead (red) 2. Negative battery lead (black) 3.
U23PE3E0.book Page 29 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ECA16521 NOTICE To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. To store the battery 1.
U23PE3E0.book Page 30 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1 2 3 4 5 6 use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. [EWA15131] 7 8 9 10 11 13 12 13 1. 2. 3. 4. 5. 6 Headlight fuse ABS solenoid fuse Electronic throttle valve fuse Fuel injection system fuse Backup fuse (for clock and immobilizer system) 6. Radiator fan fuse 7. Ignition fuse 8. Signaling system fuse 9.
U23PE3E0.book Page 31 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAU39013 Replacing a headlight bulb This model is equipped with halogen bulb headlights. If a headlight bulb burns out, replace it as follows.
U23PE3E0.book Page 32 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Connect the headlight coupler. 6. Install the headlight bulb cover by turning it clockwise. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1 1. Headlight coupler 3. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 6 1 2 1. Headlight bulb 2. Headlight bulb holder 4. Place a new headlight bulb into position, and then secure it with the bulb holder.
U23PE3E0.book Page 33 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU49721 EAU24204 Replacing a turn signal light bulb 1 1. Remove the turn signal light lens by removing the screw. Replacing a license plate light bulb 1. Remove the license plate light unit bolts. 1 1 2 1. Turn signal light bulb 2 1. Turn signal light lens 2. Screw 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 3.
U23PE3E0.book Page 34 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1 6. Place the license plate light unit in the original position, and then install the bolts. EAU49624 Replacing an auxiliary light bulb This model is equipped with two auxiliary lights. If an auxiliary light bulb burns out, replace it as follows. 1. Remove the windshield by removing the screws. 1 1. License plate light bulb socket 3. Remove the burnt-out bulb by pulling it out. 2 2 6 1 1. Windshield 2.
U23PE3E0.book Page 35 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT supported. NOTICE: Be careful not to pull the headlight leads. 2 [ECA16810] 1 5. Remove the auxiliary light bulb socket (together with the bulb) by turning the socket counterclockwise. 1 2 2 1. Panel 2. Quick fastener 3. Remove the headlight unit cover by removing the bolts. 1 1. Headlight unit 2. Headlight unit bolt 1. Auxiliary light bulb socket 1 6. Remove the burnt-out bulb by pulling it out.
U23PE3E0.book Page 36 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT 8. Install the socket (together with the bulb) by pushing it in and turning it clockwise. 9. Install the headlight unit by installing the bolts, and then tightening them to the specified torque. Tightening torque: Headlight unit bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 6 10. Install the headlight unit cover by installing the bolts. 11. Install the panel by installing the quick fasteners. 12.
U23PE3E0.book Page 37 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU42504 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough fuel. Check the battery. There is no fuel. Supply fuel. Check the fuel level in the fuel tank. 2. Battery The engine does not start. Check the battery. The engine turns over quickly. The battery is good. The engine turns over slowly.
U23PE3E0.book Page 38 Monday, July 30, 2012 8:44 AM PERIODIC MAINTENANCE AND ADJUSTMENT Engine overheating EWAT1040 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. EAU54710 Care ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM MOTORCYCLE CARE AND STORAGE ● ● 7 ● off any detergent residue using plenty of water, as it is harmful to plastic parts. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM MOTORCYCLE CARE AND STORAGE windshield. Before using them, make a test by polishing an area which does not affect your visibility. After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 3.
U23PE3E0.book Page 4 Monday, July 30, 2012 8:44 AM MOTORCYCLE CARE AND STORAGE EAU49591 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. Be sure the engine and the exhaust system are cool before covering the motorcycle. ECA10810 NOTICE ● 7 ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
U23PE3E0.book Page 5 Monday, July 30, 2012 8:44 AM MOTORCYCLE CARE AND STORAGE TIP Make any necessary repairs before storing the motorcycle.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM SPECIFICATIONS Dimensions: Overall length: 2255 mm (88.8 in) Overall width: 980 mm (38.6 in) Overall height: 1410 mm (55.5 in) Seat height: 845/870 mm (33.3/34.3 in) Wheelbase: 1540 mm (60.6 in) Ground clearance: 205 mm (8.07 in) Minimum turning radius: 2700 mm (106.
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM SPECIFICATIONS Secondary reduction ratio: 2.987 (21/25 x 32/9) Transmission type: Constant mesh 6-speed Operation: Left foot operation 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) Chassis: Frame type: Backbone Caster angle: 28.00 ° Trail: 126 mm (5.
U23PE3E0.book Page 3 Monday, July 30, 2012 8:44 AM SPECIFICATIONS Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 190.0 mm (7.48 in) Electrical system: Ignition system: TCI Charging system: AC magneto Battery: Model: YTZ12S Voltage, capacity: 12 V, 11.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: 8 Headlight: 12 V, 55.0 W × 2 Tail/brake light: LED Front turn signal light: 12 V, 10.0 W × 2 Rear turn signal light: 12 V, 10.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM CONSUMER INFORMATION EAU48612 Identification numbers Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. EAU26400 Vehicle identification number EAU26470 Model label 1 1 VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: 1. Vehicle identification number 1.
U23PE3E0.book Page 1 Monday, July 30, 2012 8:44 AM INDEX A ABS....................................................... 3-20 ABS warning light.................................... 3-7 Air filter element .................................... 6-16 Auxiliary DC jack................................... 3-35 Auxiliary light bulb, replacing ................ 6-34 Engine oil and oil filter cartridge ........... 6-11 Engine stop switch................................ 3-17 Engine trouble warning light ..................
U23PE3E0.book Page 2 Monday, July 30, 2012 8:44 AM INDEX Traction control system ........................ 3-21 Traction control system indicator/ warning light ......................................... 3-7 Troubleshooting.................................... 6-36 Troubleshooting charts ......................... 6-37 Turn signal indicator lights ...................... 3-4 Turn signal light bulb, replacing............ 6-33 Turn signal switch................................. 3-16 V Valve clearance ...........
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PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012.08-0.
