Yamaha XT1200Z(Z) 2010 User manual

2010
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 man-
ual. 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 vehi-
cle 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.
T
IP
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 disas-
sembly 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.
T
IP
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
ENew

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
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IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1”is stamped
into the right side of the frame.
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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