EasyManua.ls Logo

Yamaha XT1200Z 2010 Service Manual

Yamaha XT1200Z 2010
616 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
2010
SERVICE MANUAL
XT1200Z(Z)
23P-28197-E0
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
email: info@motomatrix.co.uk

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Yamaha XT1200Z 2010 and is the answer not in the manual?

Yamaha XT1200Z 2010 Specifications

General IconGeneral
Displacement1199 cc
Bore x Stroke98.0 mm x 79.5 mm
Compression Ratio11.0:1
Fuel SystemFuel Injection
IgnitionTCI
Transmission6-speed
Final DriveShaft
Front Tires110/80R19M/C 59V
Rear Tires150/70R17M/C 69V
Fuel Capacity23 liters
Seat Height845 mm
Wet Weight261 kg
Length2255 mm
Width980 mm
Height1410 mm
Wheelbase1540 mm
Engine TypeLiquid-cooled, 4-stroke, DOHC
Front SuspensionTelescopic fork, adjustable preload, compression and rebound damping
Rear Suspensionadjustable preload and rebound damping
Front BrakesDual 310mm discs
Rear Brakes282mm disc

Summary

GENERAL INFORMATION

IDENTIFICATION

Details on vehicle identification number and model label location.

FEATURES

Overview of key systems like FI, UBS, ABS, TCS, and instrument functions.

IMPORTANT INFORMATION

Guidelines for preparation, parts, and general service information.

BASIC SERVICE INFORMATION

Information on quick fasteners, and electrical system handling.

SPECIAL TOOLS

List of necessary special tools with part numbers and reference pages.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Motorcycle dimensions, weight, maximum load, and model variations.

ENGINE SPECIFICATIONS

Detailed engine data including type, displacement, bore, stroke, compression, oil, and fuel specs.

CHASSIS SPECIFICATIONS

Details on frame, wheels, tires, brakes, clutch, steering, and suspension.

ELECTRICAL SPECIFICATIONS

Voltage, ignition, starter, horn, fuses, and various component specifications.

TIGHTENING TORQUES

General and specific torque values for fasteners and assemblies.

LUBRICATION POINTS AND LUBRICANT TYPES

Identifies lubrication points and recommended lubricants for engine and chassis components.

COOLING SYSTEM DIAGRAMS

Visual representation of the cooling system components and flow.

CABLE ROUTING

Instructions and diagrams for routing electrical wires and cables on the motorcycle.

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

Schedule and job list for regular maintenance tasks based on odometer readings.

GENERAL MAINTENANCE AND LUBRICATION CHART

Chart detailing general maintenance and lubrication tasks at different intervals.

ADJUSTING THE VALVE CLEARANCE

Step-by-step procedure for measuring and adjusting valve clearance on a cold engine.

SYNCHRONIZING THE THROTTLE BODIES

Procedure for synchronizing throttle bodies using vacuum gauges and checking for proper operation.

CHECKING THE BRAKE FLUID LEVEL

Procedure for checking brake fluid levels in the master cylinder reservoir.

BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)

Procedures for bleeding the ABS hydraulic brake system after component removal or if faulty.

CHECKING THE TIRES

Guidelines for checking tire pressure, tread depth, wear limit, and surfaces for damage.

CHECKING AND ADJUSTING THE STEERING HEAD

Procedure for checking and adjusting steering head bearing play and tightness.

CHANGING THE ENGINE OIL

Step-by-step instructions for draining and replacing engine oil and oil filter.

CHECKING THE COOLANT LEVEL

Procedure to check the coolant level in the radiator and reservoir.

CHANGING THE FINAL GEAR OIL

Procedure to check the final gear oil level and add oil if necessary.

CHASSIS

GENERAL CHASSIS

Covers removal and installation of seats, carriers, side cowlings, and electrical components.

FRONT WHEEL

Procedures for removing, disassembling, checking, balancing, and installing the front wheel.

REAR WHEEL

Procedures for removing, disassembling, checking, and installing the rear wheel.

FRONT BRAKE

Covers removal, disassembly, checking, and installation of brake pads, calipers, and master cylinder.

REAR BRAKE

Covers removal, disassembly, checking, and installation of brake pads, calipers, and master cylinder.

ABS (ANTI-LOCK BRAKE SYSTEM)

Detailed procedures for removing, installing, checking, and testing ABS components and system.

HANDLEBAR

Procedures for removing, checking, and installing handlebar components like grips, levers, and switches.

FRONT FORK

Procedures for removing, disassembling, checking, and assembling front fork legs.

STEERING HEAD

Procedures for removing, checking, and installing steering head components and bearings.

REAR SHOCK ABSORBER ASSEMBLY

Procedures for handling, disposing, removing, checking, and installing the rear shock absorber.

SWINGARM

Procedures for removing, checking, lubricating, and installing the swingarm.

SHAFT DRIVE

Procedures for removing, disassembling, checking, and aligning final drive components and drive shaft.

ENGINE

ENGINE INSPECTION

Procedures for measuring compression pressure and general engine checks.

ENGINE REMOVAL

Step-by-step process for removing the engine, including exhaust pipe disconnection.

CAMSHAFTS

Procedures for removing, checking, and installing camshafts, sprockets, and related components.

CYLINDER HEAD

Procedures for removing, checking, and installing the cylinder head, including valve clearance.

VALVES AND VALVE SPRINGS

Procedures for removing, checking, cleaning, lapping, and installing valves, springs, and guides.

CYLINDER AND PISTONS

Procedures for removing, checking, and installing cylinders, pistons, and piston rings.

GENERATOR AND STARTER CLUTCH

Procedures for removing, checking, and installing the generator, starter clutch, and torque limiter.

ELECTRIC STARTER

Procedures for removing, disassembling, checking, and assembling the starter motor.

CLUTCH

Procedures for removing, checking, and installing clutch components, including plates and master cylinder.

PICKUP ROTOR

Procedures for removing, installing, and checking the pickup rotor and its gap.

SHIFT SHAFT

Procedures for removing, checking, adjusting, and installing the shift shaft and related components.

OIL PUMP

Procedures for removing, checking, assembling, and installing the oil pan, strainer, and oil pump.

CRANKCASE

Procedures for removing, disassembling, checking, assembling, and installing crankcase components.

CRANKSHAFT AND BALANCER

Procedures for removing, checking, and installing crankshaft, connecting rods, and balancer shafts.

TRANSMISSION

Procedures for removing, checking, assembling, and installing the transmission, shift drum, and shift forks.

MIDDLE GEAR

Procedures for removing, disassembling, checking, and aligning middle gear components.

COOLING SYSTEM

RADIATOR

Procedures for removing, checking, and installing the radiator and related hoses.

THERMOSTAT

Procedures for removing, checking, and installing the thermostat and its cover.

WATER PUMP

Procedures for removing, disassembling, checking, assembling, and installing the water pump.

FUEL SYSTEM

FUEL TANK

Procedures for removing and installing the fuel tank and fuel pump.

THROTTLE BODIES

Procedures for removing, checking, cleaning, and installing throttle bodies, injectors, and sensors.

CHECKING THE INJECTOR PRESSURE

Procedure for checking fuel injector pressure using a pressure gauge.

CHECKING THE FUEL PRESSURE

Procedure for checking fuel pressure using a fuel pressure adapter and gauge.

ADJUSTING THE THROTTLE POSITION SENSOR

Procedure for checking and adjusting the throttle position sensor angle.

ADJUSTING THE ACCELERATOR POSITION SENSOR

Procedure for checking and adjusting the accelerator position sensor angle.

INSTALLING THE THROTTLE BODY JOINTS

Procedure for installing throttle body joints onto cylinders and throttle bodies.

ELECTRICAL SYSTEM

IGNITION SYSTEM

Circuit diagram and troubleshooting for the ignition system.

ELECTRIC STARTING SYSTEM

Circuit diagram and troubleshooting for the electric starting system.

CHARGING SYSTEM

Circuit diagram and troubleshooting for the charging system.

LIGHTING SYSTEM

Circuit diagram and troubleshooting for headlights, taillights, and other lighting components.

SIGNALING SYSTEM

Circuit diagram and troubleshooting for turn signals, brake lights, horn, and hazard lights.

COOLING SYSTEM

Circuit diagram for the cooling system.

FUEL INJECTION SYSTEM

Circuit diagram, ECU self-diagnosis, and troubleshooting for the fuel injection system.

FUEL PUMP SYSTEM

Circuit diagram and troubleshooting for the fuel pump system.

IMMOBILIZER SYSTEM

Circuit diagram, general info, part replacement, key registration, and troubleshooting.

ABS (ANTI-LOCK BRAKE SYSTEM)

Circuit diagram, component chart, troubleshooting, and operation tests for the ABS system.

ELECTRICAL COMPONENTS

Diagrams and lists of various electrical components.

CHECKING THE SWITCHES

Procedures for checking continuity and operation of various motorcycle switches.

CHECKING THE BULBS AND BULB SOCKETS

Procedure for checking bulb and socket condition and continuity.

CHECKING THE FUSES

Procedure for checking fuse continuity and replacement.

CHECKING AND CHARGING THE BATTERY

Procedures for checking battery charge and charging VRLA batteries.

CHECKING THE RELAYS

Procedures for checking starter relay, turn signal/hazard relay, radiator fan motor relay, and relay unit.

CHECKING THE IGNITION COILS

Procedure for checking primary and secondary coil resistance.

CHECKING THE STARTER MOTOR OPERATION

Procedure for checking starter motor operation and troubleshooting.

CHECKING THE STATOR COIL

Procedure for checking stator coil resistance.

CHECKING THE RECTIFIER/REGULATOR

Procedure for checking charging voltage.

CHECKING THE OIL LEVEL SWITCH

Procedure for checking oil level switch resistance.

CHECKING THE FUEL SENDER

Procedure for checking fuel sender resistance at different fuel levels.

CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT

Procedure for checking fuel meter and warning light function.

CHECKING THE COOLANT TEMPERATURE SENSOR

Procedure for checking coolant temperature sensor resistance at different temperatures.

CHECKING THE THROTTLE POSITION SENSOR

Procedure for checking and adjusting the throttle position sensor angle.

CHECKING THE ACCELERATOR POSITION SENSOR

Procedure for checking and adjusting the accelerator position sensor angle.

CHECKING THE INTAKE AIR PRESSURE SENSOR

Procedure for checking intake air pressure sensor output voltage.

CHECKING THE FUEL INJECTORS

Procedures for checking injectors for obstruction and resistance.

CHECKING THE THROTTLE SERVO MOTOR

Procedures for checking throttle servo motor resistance and throttle valve operation.

TROUBLESHOOTING

GENERAL INFORMATION

General guide for troubleshooting and notes on identifying potential causes of trouble.

STARTING FAILURES

Troubleshooting steps for engine starting issues, covering fuel, ignition, electrical, and starting systems.

INCORRECT ENGINE IDLING SPEED

Troubleshooting steps for incorrect engine idling speed related to engine, fuel, and electrical systems.

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Troubleshooting steps for poor performance at medium and high speeds.

FAULTY GEAR SHIFTING

Troubleshooting steps for shifting issues, including difficulty, pedal movement, gear jumping, and clutch problems.

SHIFT PEDAL DOES NOT MOVE

Troubleshooting steps for issues where the shift pedal does not move correctly.

JUMPS OUT OF GEAR

Troubleshooting steps for when the transmission jumps out of gear.

FAULTY CLUTCH

Troubleshooting steps for clutch slippage or dragging issues.

OVERHEATING

Troubleshooting steps for engine overheating caused by coolant, radiator, water pump, or fuel system issues.

OVERCOOLING

Troubleshooting steps for engine overcooling issues.

POOR BRAKING PERFORMANCE

Troubleshooting steps for poor braking performance related to pads, discs, fluid, or calipers.

FAULTY FRONT FORK LEGS

Troubleshooting steps for issues with front fork legs, including leaks, bends, and oil levels.

UNSTABLE HANDLING

Troubleshooting steps for unstable handling related to handlebar, steering head, or front fork issues.

FAULTY LIGHTING OR SIGNALING SYSTEM

Troubleshooting steps for failures in headlights, turn signals, brake lights, horn, and other signaling components.

Related product manuals