Yamaha SUPER TENERE XT1200Z 2010 Service Manual
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Yamaha SUPER TENERE XT1200Z 2010 Service Manual

Yamaha SUPER TENERE XT1200Z 2010 Service Manual

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

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Summary of Contents for Yamaha SUPER TENERE XT1200Z 2010

  • Page 1 2010 SERVICE MANUAL XT1200Z(Z) 23P-28197-E0...
  • Page 2 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 3: Table Of Contents

    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............

  • Page 4: Identification

    IDENTIFICATION 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.

  • Page 5: Features

    FEATURES EAS20170 FEATURES EAS30340 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 6: Fi System

    FEATURES EAS23P1100 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 7: Ycc-T (Yamaha Chip Controlled Throttle)

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 8 FEATURES YCC-T system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. YCC-T CPU 6. FI CPU 7. Sensor input 8. Neutral switch 9. Crankshaft position sensor 10. Rear wheel sensor 11.

  • Page 9: Outline Of The Ubs

    FEATURES EAS23P1060 OUTLINE OF THE UBS This model is equipped with a unified brake system (UBS) that operates the rear brake when the brake lever is squeezed. When the brake lever is squeezed, the rear brake force is controlled electronically according to the brake lever input (hydraulic pressure) and vehicle speed (deceleration).
  • Page 10 FEATURES • Brake lever input and brake pedal input: Front braking and rear braking (with and without UBS oper- ation) Brake lever and brake pedal both operated A. Brake lever is operated before brake pedal B. Brake pedal is operated before brake lever a.
  • Page 11 FEATURES When the brake lever is squeezed, the front brake master cylinder pressure sensor in the hydraulic unit detects the hydraulic pressure. The ABS ECU calculates the appropriate rear brake force according to the detected hydraulic pressure and sends a signal to the rear brake hydraulic pump. The hydraulic pump pressurizes the rear brake caliper using electronic control to operate the rear brake.
  • Page 12 FEATURES a. Hydraulic pressure distribution b. Rear brake output (bars) c. Front brake input (bars) d. Rider only e. When carrying the maximum load f. Vehicle speed coefficient g. Coefficient (%) h. Speed (km/h)

  • Page 13: Outline Of The Abs

    FEATURES EAS23P1061 OUTLINE OF THE ABS 1. This model is equipped with the latest, advanced type of ABS, which has improved feeling during operation and smoother braking than previous ABS brakes. The ABS ECU detects the hydraulic pressure using the pressure sensors and controls the pressure linearly using continuously variable adjustments to obtain the appropriate pressure when the wheels have a tendency to lock or accord- ing to the operation input (hydraulic pressure) from the brake lever or brake pedal.
  • Page 14 FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. •...
  • Page 15 FEATURES a. Friction force between the tire and road e. Less slippery road surface surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d. Slip ratio (%) Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors.
  • Page 16 FEATURES a. Chassis speed d. Depressurizing phase b. Wheel speed e. Pressurizing phase c. Brake force ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control.
  • Page 17 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS also includes a highly developed self-diagnosis function. The ABS has been designed to op- erate as a conventional brake system if the ABS malfunctions.

  • Page 18: Abs Component Functions

    FEATURES ABS block diagram 1. Front brake master cylinder 10. Front brake master cylinder pressure sensor 2. Rear brake master cylinder 11. Check valve 3. Hydraulic unit assembly 12. Buffer chamber 4. Rear brake master cylinder pressure sensor 13. Inlet solenoid valve 5.
  • Page 19 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is operating prop- erly.
  • Page 20 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (outlet solenoid valves, inlet solenoid valves, a shuttle solenoid valve, and a separation solenoid valve), buffer chambers, damping chambers, hydraulic pumps, an ABS motor, hydraulic pressure sensors (front brake master cylinder pressure sensor, rear brake master cylinder pressure sensor, and rear brake caliper pressure sensor), and an ABS ECU.
  • Page 21 FEATURES 4 5 6 18 19 20 21 1. Battery 18. Rear brake inlet solenoid 2. AC magneto 19. Rear brake outlet solenoid 3. Rectifier/regulator 20. Separation solenoid valve 4. Main fuse 21. Shuttle solenoid valve 5. Main switch 22. ABS motor 6.
  • Page 22 FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was set to “ON”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.

  • Page 23: Ubs And Abs Operation

    FEATURES EAS23P1063 UBS AND ABS OPERATION The ABS hydraulic circuit consists of two systems: one for the front wheel and one for the rear wheel. Normal braking (ABS not activated and UBS not activated) Front brakes: When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
  • Page 24 FEATURES Emergency braking (ABS activated and UBS not activated) Depressurizing phase: When the front wheel (or the rear wheel) is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve closes the brake line from the brake master cylinder.
  • Page 25 FEATURES UBS (ABS not activated and UBS activated) Brake lever input only Front brakes: When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU. Therefore, when the brake lever is squeezed, the hydraulic pressure in the front brake master cylinder increases and the brake fluid is sent to the front brake calipers.
  • Page 26 FEATURES UBS (ABS activated and UBS activated) Brake lever input only Front brakes: Refer to “Emergency braking (ABS activated and UBS not activated)”. Rear brake: When the rear wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” sig- nal transmitted from the ABS ECU.

  • Page 27: Abs Self-Diagnosis Function

    FEATURES EAS23P1064 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. The ABS warning light is located on the meter assembly. Instances when the ABS warning light comes on 1.
  • Page 28 FEATURES 3. The ABS warning light comes on while riding. If the ABS warning light comes on while riding, a malfunction has been detected in the ABS or UBS. The ABS hydraulic control will not be performed. The ABS will have recourse to manual braking if this occurs.

  • Page 29: Abs Warning Light And Operation

    FEATURES The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con- nected to the ABS test coupler. EAS23P1065 ABS WARNING LIGHT AND OPERATION ABS warning light • When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off. •...
  • Page 30 FEATURES ABS and UBS function EWA23P1038 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.

  • Page 31: Outline Of The Tcs (Traction Control System)

    FEATURES EAS23P1099 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen- sors, and detects rear wheel slipping according to the difference between the wheel speeds.
  • Page 32 FEATURES 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU (electronic control unit) F. Ignition timing (retarded) 4. Traction control system switch G. Traction control system indicator light (flashes) 5. ECU (engine control unit) H.
  • Page 33 FEATURES • “TCS” “Off”: The traction control system is turned off. The system may also be automatically disabled in some riding conditions (Refer to “Resetting”). When the key is turned to “ON”, the traction control system is enabled and “TCS” “1” displays in the multi-function meter.

  • Page 34: Instrument Functions

    FEATURES • a traction control system mode display (which EAS23P1106 INSTRUMENT FUNCTIONS shows the selected traction control system mode) Multi-function meter unit • a self-diagnosis device EWA23P1041 • an LCD and tachometer brightness control WARNING mode Be sure to stop the vehicle before making The left and right set buttons, located under the any setting changes to the multi-function display, allow you to control or change the set-...
  • Page 35 FEATURES Odometer and tripmeter modes Clock 1. Odometer/tripmeter/fuel reserve tripmeter 1. Clock 2. Left set button 2. Right set button 3. Left set button Pushing the left button switches the display be- tween the odometer mode “ODO” and the trip- The clock displays when the key is turned to meter modes “TRIP 1”...
  • Page 36 FEATURES Air intake temperature mode This fuel meter is equipped with a self-diagnosis system. If a problem is detected in the electrical circuit, all display segments start flashing. If this occurs, check the electrical circuit. Refer to “SIGNALING SYSTEM” on page 8-21. Air intake temperature, coolant temperature, instantaneous fuel consumption and aver- age fuel consumption modes...
  • Page 37 FEATURES Instantaneous fuel consumption mode • The “AVE_ _._ km/L” display shows the aver- age distance that can be traveled on 1.0 L of fuel. • The “AVE_ _._ L/100 km” display shows the average amount of fuel necessary to travel 100 •...
  • Page 38 FEATURES This display indicates which traction control sys- EWA23P1042 NOTICE tem mode has been selected: “1”, “2” or “Off”. If the display indicates a fault code, the vehi- For more details on the modes and on how to cle should be checked as soon as possible select them, refer to “TCS (Traction Control Sys- in order to avoid engine damage.
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