Yamaha XT 1200 Z Service & Repair Manual

2010-2014 SERVICE MANUAL XT1200Z(Z) 23P-28197-E0

EAS20040 XT1200Z(Z) 2010 SERVICE MANUAL ©2010 by Yamaha Motor Co., Ltd. First edition, March 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. TIP Designs and specifications are subject to change without notice. EAS20081 IMPORTANT MANUAL INFORMATION 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 person- al injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer. WARNING NOTICE TIP

EAS20091 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1” is shown at the top of each page. • Sub-section titles “2” appear in smaller print than the section title. • To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each removal and disassembly section. • Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step. • Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. • A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. • Jobs “7” requiring more information (such as special tools and technical data) are described sequen- tially. 1 7 3 4 6 2 5

EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. TIP The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium-soap-based grease Wear limit, clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent (LOCTITE®). Engine oil Replace the part with a new one. G M BF B T R . . LS M S LT E New

EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9

1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES ...................................................................................................... 1-2 OUTLINE OF THE FI SYSTEM ................................................................. 1-2 FI SYSTEM................................................................................................ 1-3 YCC-T (Yamaha Chip Controlled Throttle) ................................................ 1-4 OUTLINE OF THE UBS ............................................................................ 1-6 OUTLINE OF THE ABS........................................................................... 1-10 ABS COMPONENT FUNCTIONS ........................................................... 1-15 UBS AND ABS OPERATION .................................................................. 1-20 ABS SELF-DIAGNOSIS FUNCTION....................................................... 1-24 ABS WARNING LIGHT AND OPERATION............................................. 1-26 OUTLINE OF THE TCS (Traction Control System) ................................. 1-28 INSTRUMENT FUNCTIONS ................................................................... 1-31 IMPORTANT INFORMATION ....................................................................... 1-37 PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-37 REPLACEMENT PARTS......................................................................... 1-37 GASKETS, OIL SEALS AND O-RINGS .................................................. 1-37 LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-37 BEARINGS AND OIL SEALS .................................................................. 1-38 CIRCLIPS ................................................................................................ 1-38 BASIC SERVICE INFORMATION................................................................. 1-39 QUICK FASTENERS............................................................................... 1-39 ELECTRICAL SYSTEM........................................................................... 1-40 SPECIAL TOOLS .......................................................................................... 1-44

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts. 1 1

Yamaha XT 1200 Z Service & Repair Manual

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