Yamaha XT1200Z 2010 Manuals

Yamaha XT1200Z 2010 Manuals

Manuals and User Guides for Yamaha XT1200Z 2010. We have 1 Yamaha XT1200Z 2010 manual available for free PDF download: Service Manual

Yamaha XT1200Z 2010 Service Manual

Yamaha XT1200Z 2010 Service Manual (616 pages)

Brand: Yamaha | Category: Motorcycle | Size: 81.68 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- Symbols
  5
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    YCC-T (Yamaha Chip Controlled Throttle)
    13
    
    Outline of the Ubs
    15
    
    Outline of the Abs
    19
    
    Abs Component Functions
    24
    
    Ubs and Abs Operation
    29
    
    Abs Self-Diagnosis Function
    33
    
    Abs Warning Light and Operation
    35
    
    OUTLINE of the TCS (Traction Control System)
    37
    
    Instrument Functions
    40
  - Important Information
    46
    
    Preparation for Removal and Disassembly
    46
    
    Replacement Parts
    46
    
    Gaskets, Oil Seals and O-Rings
    46
    
    Lock Washers/Plates and Cotter Pins
    46
    
    Bearings and Oil Seals
    47
    
    Circlips
    47
  - Basic Service Information
    48
    
    Quick Fasteners
    48
    
    Electrical System
    49
  - Special Tools
    53
Specifications

61
- General Specifications
  62
- Engine Specifications
  63
- Chassis Specifications
  71
- Electrical Specifications
  74
- Tightening Torques
  77
- Lubrication Points and Lubricant Types
  89
  - Engine
    89
  - Chassis
    91
- Lubrication System Chart and Diagrams
  92
  - Engine Oil Lubrication Chart
    92
  - Lubrication Diagrams
    94
- Cooling System Diagrams
  102
- Cable Routing
  104
Periodic Checks and Adjustments

135
- General Maintenance and Lubrication Chart
  138
- Introduction
  138
- Periodic Maintenance
  138
- Periodic Maintenance Chart for the Emission Control System
  138
- Checking the Fuel Line
  141
- Checking the Spark Plugs
  141
- Adjusting the Valve Clearance
  142
- Synchronizing the Throttle Bodies
  145
- Adjusting the Exhaust Gas Volume
  147
- Checking the Exhaust System
  147
- Checking the Cylinder Head Breather Hose
  148
- Replacing the Air Filter Element
  148
- Adjusting the Clutch Lever
  149
- Bleeding the Hydraulic Clutch System
  150
- Checking the Clutch Fluid Level
  150
- Adjusting the Front Disc Brake
  151
- Checking the Brake Fluid Level
  151
- Bleeding the Hydraulic Brake System (Abs)
  152
- Checking the Front Brake Pads
  153
- Checking the Rear Brake Pads
  153
- Checking and Tightening the Spokes
  154
- Checking the Brake Hoses
  154
- Checking the Wheels
  154
- Checking the Tires
  155
- Checking the Swingarm Pivot
  156
- Checking the Wheel Bearings
  156
- Lubricating the Swingarm Pivot
  156
- Checking and Adjusting the Steering Head
  157
- Checking the Centerstand
  158
- Checking the Fasteners
  158
- Checking the Front Fork
  158
- Checking the Sidestand
  158
- Checking the Sidestand Switch
  158
- Lubricating the Centerstand
  158
- Lubricating the Levers
  158
- Lubricating the Pedals
  158
- Lubricating the Sidestand
  158
- Lubricating the Steering Head
  158
- Adjusting the Rear Shock Absorber Assembly
  160
- Checking the Rear Suspension
  160
- Checking the Engine Oil Level
  161
- Changing the Engine Oil
  162
- Measuring the Engine Oil Pressure
  163
- Checking the Coolant Level
  164
- Checking the Cooling System
  164
- Changing the Coolant
  165
- Checking the Final Gear Oil Level
  166
- Adjusting the Rear Brake Light Switch
  167
- Changing the Final Gear Oil
  167
- Checking the Brake Light Switches
  167
- Checking and Lubricating the Cables
  168
- Checking the Throttle Grip Operation
  168
- Adjusting the Headlight Beams
  169
- Checking the Switches, Lights and Signals
  169
- Replacing the Headlight Bulbs
  169
- Replacing the Auxiliary Light Bulbs
  170
Chassis

171
- General Chassis
  
  174
  - Installing the Carriers
    175
  - Installing the Seats
    175
  - Installing the Abs Unit Cover
    180
  - Removing the Abs Unit Cover
    180
  - Installing the Side Cowlings
    182
  - Removing the Side Cowlings
    182
  - Installing the Electrical Components Tray
    187
  - Assembling the Headlight
    190
  - Installing the Headlight Assembly and Windshield
    190
  - Removing the Air Filter Case
    192
- Front Wheel
  
  193
- Rear Wheel
  
  202
- Front Brake
  
  209
- Rear Brake
  
  232
- ABS (Anti-Lock Brake System)
  
  239
  - Removing the Hydraulic Unit Assembly
    242
  - Checking the Hydraulic Unit Assembly
    243
  - Checking the Brake Pipes
    243
  - Installing the Hydraulic Unit Assembly
    243
  - Hydraulic Unit Operation Tests
    244
  - Trial Run
    248
- Handlebar
  
  249
  - Removing the Handlebar
    252
  - Checking the Handlebar
    252
  - Installing the Handlebar
    252
- Front Fork
  
  255
  - Removing the Front Fork Legs
    258
  - Disassembling the Front Fork Legs
    258
  - Checking the Front Fork Legs
    259
  - Assembling the Front Fork Legs
    260
  - Installing the Front Fork Legs
    264
- Steering Head
  
  265
  - Removing the Lower Bracket
    267
  - Checking the Steering Head
    267
  - Installing the Steering Head
    267
- Rear Shock Absorber Assembly
  
  269
- Swingarm
  
  273
  - Removing the Swingarm
    275
  - Checking the Swingarm
    275
  - Installing the Swingarm
    275
- Shaft Drive
  
  277
Engine

293
- Engine Inspection
  
  296
  - Measuring the Compression Pressure
    296
- Engine Removal
  
  298
  - Removing the Engine
    304
  - Installing the Engine
    304
  - Installing the Exhaust Pipe and Muffler
    305
- Camshafts
  
  306
  - Removing the Cylinder Head Cover
    310
  - Removing the Camshafts
    311
  - Checking the Camshafts
    312
  - Checking the Camshaft Sprocket
    313
  - Checking the Timing Chain Tensioners
    314
  - Checking the Decompression System
    314
  - Installing the Camshafts
    314
  - Installing the Cylinder Head Cover
    318
- Cylinder Head
  
  321
- Valves and Valve Springs
  
  324
  - Removing the Valves
    325
  - Checking the Valves and Valve Guides
    325
  - Checking the Valve Seats
    327
  - Checking the Valve Springs
    329
  - Checking the Valve Lifters
    329
  - Installing the Valves
    329
- Cylinder and Pistons
  
  333
  - Removing the Pistons
    333
  - Checking the Cylinders and Pistons
    333
  - Checking the Piston Rings
    334
  - Checking the Piston Pins
    335
  - Installing the Pistons and Cylinder
    335
- Generator and Starter Clutch
  
  338
  - Removing the Generator
    340
  - Removing the Starter Clutch
    340
  - Checking the Starter Clutch
    340
  - Checking the Torque Limiter
    341
  - Installing the Starter Clutch
    341
  - Installing the Generator
    341
- Electric Starter
  
  343
  - Checking the Starter Motor
    345
  - Assembling the Starter Motor
    346
- Clutch
  
  347
  - Removing the Clutch
    355
  - Checking the Friction Plates
    356
  - Checking the Clutch Plates
    356
  - Checking the Clutch Spring Plate
    356
  - Checking the Clutch Housing
    357
  - Checking the Clutch Boss
    357
  - Checking the Pressure Plate
    357
  - Checking the Clutch Push Rods
    357
  - Checking the Primary Driven Gear
    357
  - Installing the Clutch
    358
  - Disassembling the Clutch Master Cylinder
    359
  - Checking the Clutch Master Cylinder
    360
  - Assembling the Clutch Master Cylinder
    360
  - Installing the Clutch Master Cylinder
    360
  - Removing the Clutch Release Cylinder
    361
  - Assembling the Clutch Release Cylinder
    362
  - Installing the Clutch Release Cylinder
    362
- Pickup Rotor
  
  364
  - Removing the Pickup Rotor
    365
  - Installing the Pickup Rotor
    365
- Shift Shaft
  
  367
  - Checking the Shift Shaft
    369
  - Checking the Stopper Lever
    369
  - Installing the Shift Shaft
    369
  - Adjusting the Shift Pedal
    369
- Oil Pump
  
  371
  - Removing the Oil Pan and Oil Strainer Cover
    375
  - Checking the Oil Pump
    375
  - Checking the Relief Valve
    375
  - Checking the Oil Pipe
    375
  - Checking the Oil Strainer
    376
  - Assembling the Oil Pump
    376
  - Installing the Oil Pan
    376
  - Installing the Oil Strainer Cover
    376
- Crankcase
  
  377
  - Removing the Rear Balancer
    382
  - Disassembling the Crankcase
    382
  - Checking the Crankcase
    383
  - Checking the Rear Balancer
    383
  - Checking the Timing Chain and Timing Chain Guide (Intake Side)
    383
  - Checking the Oil Nozzles
    383
  - Assembling the Crankcase
    383
  - Installing the Rear Balancer
    387
- Crankshaft and Balancer
  
  388
  - Removing the Front Balancer Shaft
    390
  - Removing the Balancer Shaft Journal Bearings
    390
  - Removing the Crankshaft Journal Bearings
    390
  - Removing the Connecting Rods
    390
  - Checking the Crankshaft
    390
  - Checking the Connecting Rods
    392
  - Checking the Front Balancer
    393
  - Installing the Connecting Rods
    395
  - Installing the Crankshaft
    396
  - Installing the Front Balancer Shaft
    397
- Transmission
  
  398
  - Removing the Transmission
    404
  - Checking the Shift Forks
    404
  - Checking the Shift Drum Assembly
    404
  - Checking the Transmission
    404
  - Assembling the Main Axle and Drive Axle
    405
  - Installing the Transmission
    406
- Middle Gear
  
  408
Cooling System

421
- Radiator
  
  423
  - Checking the Radiator
    424
  - Installing the Radiator
    424
- Thermostat
  
  425
  - Checking the Thermostat
    426
  - Installing the Thermostat
    426
- Water Pump
  
  427
  - Disassembling the Water Pump
    429
  - Checking the Water Pump
    429
  - Assembling the Water Pump
    429
  - Installing the Water Pump
    431
Fuel System

433
- Fuel Tank
  
  434
  - Checking the Fuel Pump Body
    436
  - Installing the Fuel Pump
    436
  - Removing the Fuel Pump
    436
  - Removing the Fuel Tank
    436
  - Installing the Fuel Tank
    437
- Throttle Bodies
  
  439
  - Checking the Injectors (before Removing)
    441
  - Removing the Injectors
    441
  - Checking the Injectors
    441
  - Checking and Cleaning the Throttle Bodies
    441
  - Checking the Throttle Body Joints
    443
  - Installing the Injectors
    443
  - Checking the Injector Pressure
    443
  - Checking the Fuel Pressure
    444
  - Adjusting the Throttle Position Sensor
    445
  - Adjusting the Accelerator Position Sensor
    445
  - Installing the Throttle Body Joints
    446
Electrical System

447
- General Information
  447
- Ignition System
  
  450
  - Circuit Diagram
    450
  - Engine Stopping Due to Sidestand Operation
    452
  - Troubleshooting
    453
- Electric Starting System
  
  456
  - Circuit Diagram
    456
  - Starting Circuit Cut-Off System Operation
    458
  - Troubleshooting
    459
- Charging System
  
  462
  - Circuit Diagram
    462
  - Troubleshooting
    464
- Lighting System
  
  466
  - Circuit Diagram
    466
  - Troubleshooting
    468
- Signaling System
  
  470
  - Circuit Diagram
    470
  - Troubleshooting
    472
- Cooling System
  
  476
  - Circuit Diagram
    476
  - Troubleshooting
    478
- Fuel Injection System
  
  480
  - Circuit Diagram
    480
  - Ecu Self-Diagnostic Function
    482
  - Troubleshooting Method
    483
  - Diagnostic Mode
    483
  - Troubleshooting Details
    485
  - Diagnostic Code Table
    522
- Fuel Pump System
  
  524
  - Circuit Diagram
    524
  - Troubleshooting
    526
- Immobilizer System
  
  528
  - Circuit Diagram
    528
  - General Information
    530
  - Part Replacement and Key Code Registration Requirements
    530
  - Troubleshooting
    534
  - Self-Diagnosis Fault Code Indication
    534
- Abs (Anti-Lock Brake System)
  
  538
- Electrical Components
  
  582
  - Checking the Switches
    586
  - Checking the Bulbs and Bulb Sockets
    589
  - Checking the Fuses
    590
  - Checking and Charging the Battery
    591
  - Checking the Relays
    594
  - Checking the Turn Signal/Hazard Relay
    595
  - Checking the Relay Unit (Diode)
    596
  - Checking the Ignition Coils
    596
  - Checking the Ignition Spark Gap
    597
  - Checking the Crankshaft Position Sensor
    597
  - Checking the Lean Angle Sensor
    598
  - Checking the Starter Motor Operation
    598
  - Checking the Stator Coil
    599
  - Checking the Rectifier/Regulator
    599
  - Checking the Oil Level Switch
    599
  - Checking the Fuel Sender
    600
  - Checking the Fuel Meter/Fuel Level Warning Light
    600
  - Checking the Oil Level Warning Light
    601
  - Checking the Radiator Fan Motor
    601
  - Checking the Coolant Temperature Sensor
    601
  - Checking the Throttle Position Sensor
    602
  - Checking the Accelerator Position Sensor
    602
  - Checking the Intake Air Pressure Sensor
    603
  - Checking the Intake Air Temperature Sensor
    604
  - Checking the Fuel Injectors
    604
  - Checking the Throttle Servo Motor
    604
Troubleshooting

607
- General Information
  608
- Incorrect Engine Idling Speed
  608
- Starting Failures
  608
- Troubleshooting
  608
- Faulty Clutch
  609
- Faulty Gear Shifting
  609
- Jumps out of Gear
  609
- Poor Medium-And-High-Speed Performance
  609
- Shift Pedal Does Not Move
  609
- Faulty Front Fork Legs
  610
- Overcooling
  610
- Overheating
  610
- Poor Braking Performance
  610
- Unstable Handling
  610
- Faulty Lighting or Signaling System
  611
  - Wiring Diagram
    612
  - COLOR Codes
    612
  - Wiring Diagram
    615

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