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Yamaha · Shim-adjusted overhead-cam four-stroke twin, dry sump, gearbox shares engine oil, shaft drive

Worldcrosser (1199 cc)

Library entry covers 2011-2017

38 factory 28 guideline

Published source

Yamaha XT1200Z Super Tenere 2016 Owner's Manual 2BS-28199-22 (Australia, English), periodic maintenance charts pp.7-3 to 7-6, TIPs pp.7-3 and 7-7

Factory owner's handbook. Covers XT1200Z Super Tenere; 2016 Australia owner's manual 2BS-28199-22, English. Chart columns 1000/10000/20000/30000/40000 km (600/6000/12000/18000/24000 mi) plus annual check; from 50000 km (30000 mi) repeat the maintenance intervals starting from 10000 km (6000 mi); annual checks every year except if a kilometer-based (UK: mileage-based) maintenance is performed instead. Liquid cooled, fuel injected, shaft final drive (final gear oil), hydraulic clutch.

Open the source

66 items for a 2015 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Shaft
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2015 Yamaha Worldcrosser (1199 cc)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

Every 3,000 mi or 12 months

3 items

Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 3,000 mi

1 item

Wheels (check rim runout and spokes for damage, tighten all spokes)

Wheels and tires

Factory

Factory: At the initial 1000 km (600 mi) and every 5000 km (3000 mi) thereafter, printed as text; dealer item (p.7-4)

Every 4,000 mi or 12 months

1 item

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 6,000 mi or 12 months

23 items

Change engine oil

Engine

Factory

Manual: Engine oil (change, check oil level and vehicle for oil leakage). Factory: Every column incl. 1000 km (600 mi) initial; annual check; not a dealer item (p.7-6)
Chassis fasteners (make sure that all nuts, bolts and screws are properly tightened)

Engine

Factory

Factory: Marked 10000-40000 km; annual check; dealer item (p.7-5)
Inspect coolant hoses and clamps

Engine

Guideline
Lights, signals and switches (check operation, adjust headlight beam)

Engine

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.7-6)
Shift pedal pivot shaft (lubricate with lithium-soap-based grease)

Engine

Factory

Factory: Marked 10000-40000 km; annual check; not a dealer item (p.7-5)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip (check operation, check throttle grip free play and adjust if necessary, lubricate cable and grip housing). Factory: Marked 10000-40000 km; not at initial; annual check; dealer item (p.7-6)
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line (check fuel hoses for cracks or damage). Factory: Marked 10000-40000 km (6000-24000 mi); not at 1000 km initial; annual check; dealer item (p.7-3)
Synchronize throttle bodies

Fuel and air

Factory

Manual: Fuel injection system (adjust synchronization). Factory: Marked 10000-40000 km; not at 1000 km initial; annual check; dealer item (p.7-3)
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Clutch lever pivot shaft (lubricate with silicone grease)

Primary and gearbox

Factory

Factory: Marked 10000-40000 km; annual check; not a dealer item (p.7-5)
Check final drive for leaks and bearing play

Final drive

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand (check operation, lubricate with lithium-soap-based grease). Factory: Marked 10000-40000 km; annual check; not a dealer item (p.7-5)
Sidestand switch (check operation)

Rear suspension and frame

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.7-5)
Brake lever pivot shaft (lubricate with silicone grease)

Brakes

Factory

Factory: Marked 10000-40000 km; annual check; not a dealer item (p.7-5)
Brake pedal pivot shaft (lubricate with lithium-soap-based grease)

Brakes

Factory

Factory: Marked 10000-40000 km; annual check; not a dealer item (p.7-5)
Check brake pads and discs

Brakes

Factory

Manual: Front brake (check operation, fluid level and vehicle for fluid leakage; replace brake pads whenever worn to the limit). Factory: Check marked every column incl. 1000 km initial; annual check; pads replaced whenever worn to the limit, printed as text; dealer item (p.7-4)
Front and rear brake switches (check operation)

Brakes

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.7-6)
Rear brake (check operation, fluid level and vehicle for fluid leakage; replace brake pads whenever worn to the limit)

Brakes

Factory

Factory: Check marked every column incl. 1000 km initial; annual check; pads replaced whenever worn to the limit, printed as text; dealer item (p.7-4)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth and for damage, replace if necessary, check air pressure, correct if necessary). Factory: Marked 10000-40000 km; annual check; dealer item (p.7-4)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables (lubricate). Factory: Marked 10000-40000 km; annual check; not a dealer item (p.7-6)
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi

8 items

Muffler and exhaust pipe (check the screw clamp(s) for looseness)

Engine

Factory

Factory: Every column incl. 1000 km (600 mi) initial; no annual check; dealer item (p.7-3)
Clutch (check operation, fluid level and vehicle for fluid leakage)

Primary and gearbox

Factory

Factory: Hydraulic clutch. Every column incl. 1000 km (600 mi) initial; no annual check; dealer item (p.7-4)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check bearing play and steering for roughness). Factory: Every column incl. 1000 km (600 mi) initial; no annual check; dealer item (p.7-5)
Front fork (check operation and for oil leakage)

Front end

Factory

Factory: Marked 10000-40000 km; no annual check; no fork oil change interval printed; dealer item (p.7-5)
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Rear suspension relay arm and connecting arm pivoting points (check operation). Factory: Marked 10000-40000 km; no annual check; no lubrication interval printed for this row; dealer item (p.7-6)
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assembly (check operation and shock absorber for oil leakage). Factory: Marked 10000-40000 km; no annual check; dealer item (p.7-5)
Swingarm (check operation and for excessive play)

Rear suspension and frame

Factory

Factory: Marked 10000-40000 km; no annual check; dealer item (p.7-5)
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check bearings for looseness or damage). Factory: Marked 10000-40000 km; no annual check; dealer item (p.7-4)

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi

4 items

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (check condition, clean and regap). Factory: Marked at 10000 and 30000 km (6000/18000 mi); no annual check; dealer item (p.7-3)
Replace oil filter

Engine

Factory

Manual: Engine oil filter cartridge (replace). Factory: Marked at 1000, 20000 and 40000 km (600/12000/24000 mi); no annual check; not a dealer item (p.7-6)
Replace spark plugs

Engine

Factory

Manual: Spark plugs (replace). Factory: Marked at 20000 and 40000 km (12000/24000 mi); no annual check; dealer item (p.7-3)
Change final drive (rear drive) oil

Final drive

Factory

Manual: Final gear oil (change). Factory: Change marked at 1000, 20000 and 40000 km (600/12000/24000 mi); check oil level and vehicle for oil leakage marked at 1000, 10000 and 30000 km; no annual check; not a dealer item (p.7-6)

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 20,000 mi or 4 years

2 items

Lubricate drive shaft splines / check U-joint

Final drive

Guideline
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 24,000 mi

2 items

Check and adjust valve clearances

Engine

Factory

Manual: Valves (check valve clearance, adjust). Factory: Every 40000 km (24000 mi), printed as text; dealer item (p.7-3)
Replace air filter element

Fuel and air

Factory

Manual: Air filter element (replace). Factory: Marked at 40000 km (24000 mi) only; no annual check; dealer item. TIP: disposable oil-coated paper element, must not be cleaned with compressed air; replace more frequently when riding in unusually wet or dusty areas (p.7-4, 7-7)

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 30,000 mi

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate with lithium-soap-based grease). Factory: Every 50000 km (30000 mi), printed as text; dealer item (p.7-5)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm (lubricate with lithium-soap-based grease). Factory: Every 50000 km (30000 mi), printed as text; dealer item (p.7-5)

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Replace hydraulic clutch fluid

Primary and gearbox

Factory

Manual: Clutch fluid (change). Factory: No separate chart row; TIP p.7-7: every two years replace the internal components of the clutch master and release cylinders and change the clutch fluid; replace clutch hoses every four years and if cracked or damaged (p.7-7)
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (change). Factory: Every 2 years, printed as text; dealer item. TIP: every two years also replace the internal components of the brake master cylinders and calipers (p.7-4, 7-7)

Every 3 years

1 item

Replace coolant

Engine

Factory

Manual: Cooling system (change coolant). Factory: Every 3 years, printed as text; check coolant level and vehicle for coolant leakage marked 10000-40000 km and annually; dealer item (p.7-6)

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses (replace). Factory: Every 4 years, printed as text; check for cracks or damage and for correct routing and clamping marked 10000-40000 km and annually; dealer item. TIP: replace the brake and clutch hoses every four years and if cracked or damaged (p.7-4, 7-7)
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.