2010–2013 Yamaha XT1200Z(Z) Super Tenere Service Manual (P/N 23P-28197-E0)

This Yamaha service manual covers the 2010–2013 XT1200Z(Z) Super Tenere and identifies the 23P1, 23P2, and 23P3 market variants. Publication 23P-28197-E0 is the first edition, issued in March 2010.

• Engine and transmission: Engine removal, valve and camshaft service, crankshaft and balancer inspection, wet-clutch repair, and gearbox disassembly and reassembly.

• Shaft drive: Final-drive disassembly, gear backlash adjustment, pinion and ring gear alignment, bearing replacement, and middle-gear setup.

• Brakes and ABS: Caliper and master-cylinder service, ABS bleeding, hydraulic-unit removal and installation, operation tests, and fault-code diagnosis.

• Suspension and wheels: Front-fork overhaul, steering-head bearing service, rear suspension linkage inspection, wheel assembly service, spoke checks, and wheel-sensor inspection.

• Fuel injection: Throttle-body synchronization, injector inspection, fuel-pressure testing, and throttle-position and accelerator-position sensor adjustment.

• Cooling system: Radiator inspection, thermostat testing, water-pump disassembly, impeller inspection, and seal installation.

• Electrical troubleshooting: Ignition, starting and charging checks, FI diagnostic-mode tables, immobilizer fault diagnosis, key registration, and system-specific circuit diagrams.

Yamaha wrote this manual primarily for its dealers and qualified mechanics; it assumes a working knowledge of motorcycle mechanics and repair techniques.

Engine, Clutch, and Shaft Drive

The engine chapter goes beyond removal and installation. It covers valve seats and guides, cylinder and piston inspection, crankcase separation, crankshaft bearing selection, and balancer inspection. Camshaft installation includes timing-mark illustrations and timing-chain tensioner checks.

Clutch service extends to the hydraulic master and release cylinders. Transmission procedures cover the shift forks, shift drum, main axle, and drive axle, with exploded views and inspection criteria for the internal parts.

Final-drive repair includes shim calculations, gear alignment, and ring-gear clearance checks. The crankshaft section also warns that interchanging journal bearings can alter oil clearance and damage the engine.

Fuel Injection and Electronic Controls

The nine-chapter manual pairs FI fault-code tables with circuit checks, diagnostic-mode readouts, and reinstatement conditions. These references help distinguish a sensor problem from a wiring or connector fault before components are replaced.

YCC-T throttle control, the Unified Brake System (UBS), and the Traction Control System (TCS) receive system-specific explanations. D-mode operation and sensor and actuator tests provide further context for electronic-control diagnosis.

Throttle-body synchronization includes a warning about disturbing the factory-marked reference bypass screw, which can cause rough idling and improper throttle-body operation. The special-tool list identifies vacuum gauge 90890-03094 and Vacuummate YU-44456 for this work.

The immobilizer section adds a parts-replacement and key-registration chart, registration procedures, and fault-code indications. It distinguishes the requirements following lost keys, ECU replacement, and immobilizer-unit replacement.

ABS, Wheels, and Suspension

Brake coverage includes the linked system’s bleeding procedure, hydraulic-unit operation tests, and stored-fault diagnosis. The ABS coupler location chart supports connector identification during electrical checks.

The ABS ECU and hydraulic unit form a non-disassemblable assembly. The procedures cover removal, inspection, installation, and replacement rather than an internal hydraulic-unit overhaul.

Chassis procedures include fork disassembly and assembly, steering-bearing replacement, wheel balancing, and suspension-linkage inspection. Use appropriate protective equipment and securely support the motorcycle before diagnosis or teardown, particularly during brake and suspension work.

Cooling, Lubrication, and System Diagrams

Water-pump service includes bearing and seal inspection, impeller checks, and assembly details. Radiator and thermostat procedures accompany the cooling-system specifications.

The engine oil lubrication chart, cooling system diagrams, ABS block diagram, and TCS block diagram explain fluid paths and control relationships. Cable-routing views and exploded component drawings support component identification and reassembly.

Examples of Valve, Compression, and Coolant Data

Intake valve clearance is specified as 0.10–0.16 mm on a cold engine at room temperature. For the warmed-engine compression check, the standard pressure is 680 kPa at sea level and 250 r/min.

Cooling specifications distinguish the 1.83 L radiator capacity, including all routes, from the separate 0.26 L coolant reservoir capacity at the maximum level mark.

Searchable Text, Bookmarks, and Wiring Sheets

Search and diagram detail: Searchable PDF text and embedded chapter and section bookmarks support navigation. Small connector labels and wire codes require zooming. The full wiring diagram is included in black-and-white and color versions.

The download contains one printable, English-language 616-page PDF. That total includes the cover and preliminary pages, five blank pages, the rear cover, and both large-format wiring-diagram sheets.