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

XT 1200

Library entry covers 2010-2019

30 factory 23 guideline

Published source

Yamaha XT1200Z Owner's Manual 23P-28199-E0 (English), Periodic maintenance charts pp.6-3 to 6-7

Factory owner's handbook. Covers 2010-2011 (XT1200Z Super Tenere, EU owner's manual 23P-28199-E0, printed Mar 2010).

Open the source

53 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: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2015 Yamaha XT 1200

On the road: every 300 km

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 500 km

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 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

Every 5,000 km or 12 months

1 item

Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 5,000 km

1 item

Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Wheels (check runout, spoke tightness; tighten spokes). Factory: At initial 1000km (600mi) and every 5000km (3000mi) thereafter

Every 6,500 km or 12 months

1 item

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 9,500 km or 12 months

4 items

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.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check final drive for leaks and bearing play

Final drive

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

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

Every 10,000 km or 12 months

9 items

Change engine oil

Engine

Factory

Manual: Engine oil (change). Factory: Cols 1000km(600mi) initial, then 10000km(6000mi) spacing to 40000km; annual check
Chassis fasteners (check tightness)

Engine

Factory

Factory: 10000km columns and annual check
Inspect coolant hoses and clamps

Engine

Factory

Manual: Cooling system (check coolant level and leakage). Factory: 10000km columns and annual check
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip housing and cable (check free play, lubricate). Factory: 10000km columns and annual check
Synchronize throttle bodies

Fuel and air

Factory

Manual: Fuel injection system (adjust synchronization). Factory: 10000km columns and annual check
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand, centerstand (check operation, lubricate). Factory: 10000km columns and annual check
Check brake pads and discs

Brakes

Factory

Manual: Front/rear brake (check operation, fluid level, leakage). Factory: Every column incl. initial; pads replaced whenever worn to limit
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth, damage, pressure). Factory: 10000km columns and annual check
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables; lever and pedal pivots (lubricate). Factory: 10000km columns and annual check

Every 10,000 km

8 items

Muffler and exhaust pipe (check screw clamps)

Engine

Factory

Factory: Marked 1000km initial, then every 10000km
Clutch (check operation, fluid level and leakage)

Primary and gearbox

Factory

Factory: Marked 1000km initial, then every 10000km
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check play and roughness). Factory: Marked 1000km initial, then every 10000km
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork (check operation and oil leakage). Factory: 10000km columns
Check swingarm bushes for play

Rear suspension and frame

Factory

Manual: Swingarm (check operation and excessive play). Factory: 10000km columns
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Rear suspension relay arm and connecting arm pivots (check operation). Factory: 10000km columns
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assembly (check operation and oil leakage). Factory: 10000km columns
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check looseness or damage). Factory: 10000km columns

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 20,000 km

4 items

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (check condition, clean and regap). Factory: Marked at 10000km and 30000km
Replace oil filter

Engine

Factory

Manual: Engine oil filter cartridge (replace). Factory: Marked 1000km initial, 20000km, 40000km
Replace spark plugs

Engine

Factory

Manual: Spark plugs (replace). Factory: Marked at 20000km and 40000km
Change final drive (rear drive) oil

Final drive

Factory

Manual: Final gear oil (change). Factory: Marked 1000km initial, 20000km, 40000km

Every 24,000 km 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 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 32,000 km 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 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km

2 items

Check and adjust valve clearances

Engine

Factory

Manual: Valves (check clearance, adjust). Factory: Every 40000 km (24000 mi); from 50000km repeat intervals from 10000km
Replace air filter element

Fuel and air

Factory

Manual: Air filter element (replace). Factory: Marked at 40000km (24000mi) only

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 50,000 km

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate, lithium-soap grease). Factory: Every 50000 km (30000 mi)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm (lubricate, lithium-soap grease). Factory: Every 50000 km (30000 mi)

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
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Brake and clutch master/caliper/release cylinder internals (replace). Factory: Every two years (TIP under chart)
Replace brake fluid

Brakes

Factory

Manual: Brake and clutch fluids (change). Factory: Every two years (TIP under chart)

Every 3 years

1 item

Replace coolant

Engine

Factory

Manual: Cooling system (change coolant). Factory: Every 3 years

Every 4 years

2 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake and clutch hoses (replace). Factory: Every 4 years; checked every 10000km and annually

Every 6 years

1 item

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.