Yamaha PRO HAULER YXP1000 Owner'S Manual Download Page 75

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8-21

2. Check the brake pedal free play by

pressing against the pedal with two fin-
gers (using light force) and measuring
the distance the pedal travels before re-
sistance is felt.

a. Brake pedal free play

3. If the free play distance needs adjusting,

loosen the locknut and turn the adjusting
nut in or out (in 180° increments only,
due to the cam shape of adjuster), until
the free play specification is met. Then
tighten the locknut to the specified
torque.

1. Locknut

2. Adjusting nut

Brake pedal free play:

20–25 mm (0.79–0.98 in)

YXP700

UJW410.book Page 21 Monday, December 15, 2003 4:36 PM

Summary of Contents for PRO HAULER YXP1000

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Page 3: ...e features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING _ Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operating ...

Page 4: ...nd this manual If you have any questions concerning this manual please consult your Yamaha dealer The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the utility vehicle occupants a bystander or a person inspecting or repairing the utility vehicle CAUTION This message describes special pre...

Page 5: ...Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited YXP700 YXP1000 OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition December 2003 All rights reserved Any reprinting or unauthorized use without the written permission of UJW410 book Page 2 Monday December 15...

Page 6: ...n switch 4 1 Oil level warning light 4 2 Fuel tank cap 4 2 Drive select lever 4 3 1 2 3 4 Cargo bed 4 7 Trailer hitch bracket 4 11 PRE OPERATION CHECKS 5 1 Pre operation check list 5 2 Brakes 5 3 Fuel 5 4 Engine oil 5 5 Transmission oil 5 5 Accelerator pedal 5 6 Steering 5 6 Fittings and fasteners 5 6 Lights 5 6 Switches 5 6 Tires 5 7 OPERATION 6 1 Starting a cold engine 6 1 5 6 UJW410 book Page 1...

Page 7: ... maintenance lubrication 8 3 Exhaust emission control system and components 8 5 Drive belt 8 14 Battery 8 15 Fuse replacement 8 16 Transmission oil 8 17 Wheel removal 8 18 Wheel installation 8 19 Brake adjustment 8 20 Brake pedal free play adjustment 8 20 Replacing a headlight bulb 8 22 Adjusting a headlight beam 8 23 Replacing a taillight bulb 8 24 CLEANING AND STORAGE 9 1 Draining the fuel 9 1 E...

Page 8: ...YAMAHA MOTOR CORPORATION U S A VEHICLE LIMITED WARRANTY 12 1 YAMAHA EXTENDED SERVICE Y E S 13 1 12 13 UJW410 book Page 3 Monday December 15 2003 4 36 PM ...

Page 9: ...UJW410 book Page 4 Monday December 15 2003 4 36 PM ...

Page 10: ... vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a re placement label is available from your Yamaha dealer YXP700 UJW410 book Page 1 Monday December 15 2003 4 36 PM ...

Page 11: ...1 2 3 4 5 6 7 8 9 10 11 12 13 9 UJW410 book Page 2 Monday December 15 2003 4 36 PM ...

Page 12: ...xtremely flammable Keep heat sparks and open flame away from fuel tank and fuel lines Do not add fuel while engine is running or hot Do not modify fuel system Service should be performed by dealer or qualified personnel L essence est exstrêmement inflammable Garder étincelles flammes et chaleur loin du réservoir à essence et des tuyaux à carburant Ne pas ajouter d essence pendant que le moteur est...

Page 13: ...8 00 Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury Never load more than 68 kg 150 lbs tongue weight on the towing bracket Do not tow more than 227 kg 500 lbs rolling weight trailer plus cargo Allow for increased braking distance and use extreme caution when operating on inclines Read carefully the loading information and trailer hit...

Page 14: ...YXP1000 7 UJW410 book Page 5 Monday December 15 2003 4 36 PM ...

Page 15: ... a b l e t o p a s s e n g e r c a r s Severe INJURY or DEATH can result if you ignore the following Maximum Load in Cargo Bed 500 lb 227 kg Never carry passengers or fill fuel containers in cargo bed Cargo can affect handling and stability Read Owner s Manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain...

Page 16: ...6 7 8 ENGINE AIR INDEX California only UJW410 book Page 7 Monday December 15 2003 4 36 PM ...

Page 17: ... 1 Steering wheel 2 Seat 3 Battery 4 Taillight 5 Rear tire 6 Fuel tank 7 Drive select lever 8 Starter choke 9 Front tire 10 Front bumper 11 Headlight 12 Accelerator pedal 13 Brake pedal 14 Parking brake pedal 15 Auxiliary DC jack UJW410 book Page 1 Monday December 15 2003 4 36 PM ...

Page 18: ...e remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number UJW410 book Page 2 Monday December 15 2003 4 36 PM ...

Page 19: ...d on to the grab rail at all times while the vehicle is in motion Never operate this vehicle on any public Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experi ence Never attempt jumps or other stunts Always inspect your vehicle each time you use it to be sure it is in safe operati...

Page 20: ...r enough ahead of you Never go over the top of a slope at speed if you cannot see Always check for obstacles before operat ing in a new area Never operate the vehicle in fast flowing water or water deeper than 15 cm 6 in Remember that wet brakes may have re duced stopping ability Test your brakes af ter leaving water If necessary apply them several times to let friction dry out the lin ings Always...

Page 21: ...e and distributed evenly from side to side Be sure cargo is secured so that it cannot move around during opera tion Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking UJW410 book Page 3 Monday December 15 2003 4 36 PM ...

Page 22: ... can be removed in this position only ON All electrical circuits except for the headlights and taillights are switched on The utility vehicle can be operated ON All electrical circuits are switched on The headlights and taillights come on The utility vehicle can be operated UJW410 book Page 1 Monday December 15 2003 4 36 PM ...

Page 23: ...f the light comes on stop the engine check the engine oil level and add oil as necessary See page 8 9 8 10 1 Oil level warning light CAUTION Always make sure there is enough engine Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap UJW410 book Page 2 Monday December 15 2003 4 36 PM ...

Page 24: ... either forward or in reverse After coming to a complete stop shift the lever to the desired position NOTE The back up buzzer will sound when the drive select lever is shifted to R Lever position Vehicle movement F FORWARD R REVERSE UJW410 book Page 3 Monday December 15 2003 4 36 PM ...

Page 25: ...or pedal Brake pedal Press the brake pedal down to slow or stop the utility vehicle 1 Brake pedal NOTE The engine stops when the utility vehicle comes to a complete stop Action Vehicle speed Depress pedal Increase Release pedal Decrease 1 1 UJW410 book Page 4 Monday December 15 2003 4 36 PM ...

Page 26: ...icle 1 Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal Starter choke Pull the starter choke knob out and hold it when starting a cold engine Release it after the engine starts 1 Starter choke knob 1 1 UJW410 book Page 5 Monday December 15 2003 4 36 PM ...

Page 27: ...jack should only be used for short periods if the utility vehicle is not being operated 1 Auxiliary DC jack cap 1 Set the main switch to ON 2 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A UJW410 book Page 6 Monday December 15 2003 4 36 PM ...

Page 28: ...e used for extended periods when the utility vehicle is not being operated or with the main switch set to ON the battery will lose its charge and starting the engine may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that get hot because the jack can be damaged Cargo bed 1 Cargo bed UJW410 book Page 7 Monday December 15 2003 4 36 PM ...

Page 29: ... 1 Tailgate 2 Latch 2 To open Unhook the latches and then lower the tail gate To close Place the tailgate in its original position and Lifting and lowering the cargo bed 1 Cargo bed release lever UJW410 book Page 8 Monday December 15 2003 4 36 PM ...

Page 30: ...ion Make sure that the latch for the cargo bed is properly en gaged Maximum load limit 113 kg 250 lb YXP700 227 kg 500 lb YXP1000 WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load for this cargo bed Cargo should be properly distributed Reduce speed ...

Page 31: ...WARNING POTENTIAL HAZARD Pinch point WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame or the seat backs when the bed is being lowered HOW TO AVOID THE HAZARD Before closing the cargo bed be sure others are standing away from the utility vehicle and that no one is sitting on the seat Keep hands and fingers away from the space between the cargo bed and seat ba...

Page 32: ...le fuel container WHAT CAN HAPPEN Static electricity sparks can ignite fuel vapors The plastic bed is not grounded increasing the risk of static electricity build up HOW TO AVOID THE HAZARD Do not refill fuel containers in the plastic bed Set fuel container on the ground and touch the nozzle to the container before removing the container cap Keep nozzle in contact with can inlet when filling Tight...

Page 33: ...ARD Failure to inspect the vehicle before op erating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always follow the inspection and maintenance proce dures and schedules described in the Owner s Manu...

Page 34: ...if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 5 8 9 8 10 Transmission oil Check for leakage 5 5 8 17 8 18 Accelerator pedal Check for proper accelerator pedal operation 5 6 Steering Check for proper operation 5 6 Fittings and fasteners Check all fittings and fasteners 5 6 Lights and switches Check for proper operation 5 6 8 22 8 24 Wheels and tires Check tire pressur...

Page 35: ...e sure they are working properly If the brakes do not provide proper braking per formance inspect the brake system See pages 8 20 8 22 WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any pr...

Page 36: ...rs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha because it may cause fuel s...

Page 37: ...RD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fu...

Page 38: ...the steering Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the utility vehicle to a Yamaha dealer or refer to the Ser vice Manual for the correct tightening torques Lights Check the headlights and taillights to make sure they are in working condition Repair as necessary for proper operation WARNING POTENTIAL HAZARD Checking operation of the ...

Page 39: ... improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control increasing your risk of acci dent HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yamaha Motor Manufac turing Corporation of America for this model Other tire combinations are not recommended YXP...

Page 40: ...cified could cause the tire to dislodge from the rim under severe riding conditions The following are Manufacturer Size Front DURO 22 11 10 6 PLY Rear DURO 22 11 10 6 PLY 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast...

Page 41: ...Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit UJW410 book Page 9 Monday December 15 2003 4 36 PM ...

Page 42: ... select lever to F for forward or R for reverse CAUTION 2 Turn the main switch to ON or ON WARNING POTENTIAL HAZARD Depressing accelerator pedal while turning on the main switch WHAT COULD HAPPEN The utility vehicle could start moving UJW410 book Page 1 Monday December 15 2003 4 36 PM ...

Page 43: ...tarter choke knob NOTE The choke is not required when the engine is warm 4 Check that your path is clear in the direc tion you plan to go and slowly depress the accelerator pedal The engine will start and the utility vehicle will start to move 1 Accelerator pedal NOTE The parking brake automatically releases 1 1 UJW410 book Page 2 Monday December 15 2003 4 36 PM ...

Page 44: ...used Press the accelerator pedal slightly Stopping To stop the utility vehicle gradually press down on the brake pedal When the utility vehicle has come to a stop apply the parking brake pedal and turn the main switch to OFF 1 Brake pedal 2 Parking brake pedal CAUTION 2 1 UJW410 book Page 3 Monday December 15 2003 4 36 PM ...

Page 45: ... or suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are operating could affect your ability to control the vehi cle Do not mount an accessory where it could interfere with your ability to control the vehi cle Examples include but are...

Page 46: ...railer on the scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in the cargo bed as close to the center of the vehicle as possible Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around ...

Page 47: ...harp turns unless at very slow speeds Avoid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity fo...

Page 48: ... attention to the safety information on pages 3 1 3 3 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a...

Page 49: ... Maximum load limit 318 kg 700 lb YXP700 454 kg 1000 lb YXP1000 WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when ca...

Page 50: ...erator pedal slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Avoid higher speeds until you are thoroughly familiar with When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to lose traction re ducing control and increasing the possibility of an accident The en...

Page 51: ...efully which slopes you attempt to drive on Avoid slopes with slippery surfaces or ones where you will not be able to see far Slow down when you reach the crest of the hill Maximum slope angle 15 WARNING POTENTIAL HAZARD Operating on steep slopes WHAT CAN HAPPEN The utility vehicle can overturn more easily on steep slopes than on level sur faces or gentle inclines HOW TO AVOID THE HAZARD Never ope...

Page 52: ...that may appear If you must turn to avoid an ob stacle do not turn at a sharp angle that could allow the vehicle to pitch or roll over Go as slowly as possible If you are starting to go too fast apply the brakes gently Avoid sudden application of the brakes which could WARNING POTENTIAL HAZARD Going down a slope improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overtur...

Page 53: ...gh water deeper than 15 cm 6 in or fast flowing water Wet brakes may have reduced effectiveness After leaving the water test your brakes If necessary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn HOW TO AVOID TH...

Page 54: ...ch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger WARNING POTENTIAL HAZARD Operating in rough terrain WHAT CAN HAPPEN The vehicle can overturn or go out of control HOW TO AVOID THE HAZARD Always be alert to changing terrain Go slowly ...

Page 55: ...e vehicle The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs NOTE _ If you do not have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the WARNING POTENTIAL HAZARD Servicing an engine while it is running...

Page 56: ...which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through im proper installation or use of accesso ries All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be in stalled and used according to instruc UJW410 book Page 2 Monday December 15 2003 4 36 PM ...

Page 57: ... 1 6 6 12 km mi 160 100 1 000 600 1 000 600 2 000 1 200 hours 20 125 125 250 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element and pre air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check starter operation Adjust if necessary Exhaust system Check for l...

Page 58: ...operation and for leakage Correct if necessary Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Engine mounts Check for cracks or damage Check bolt tightness Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 6 6 12 km mi 160 100 1 000 600 1 000 600 2 000 ...

Page 59: ...t version of the SAE s recommended practice document J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic Item Acronym CARB ASSY LH JT CARBURETOR 2 JT CARBURETOR 1 CARB Carburetor T C I MAGNETO ASSY PLUG SPARK El Electronic Ignition CRANKCASE 1 HEAD CYLINDER 1 PCV Positive Cran...

Page 60: ... the seat must be lifted 1 Seat 2 Prop rod Cargo bed Lift the cargo bed to service the engine for the YXP1000 3 Lift the cargo bed up until the end of the prop rod hooks onto the prop rod guide to support the cargo bed 1 Cargo bed release lever UJW410 book Page 6 Monday December 15 2003 4 36 PM ...

Page 61: ...erate the utility vehicle with the cargo bed in the up position Inju ry could occur if the cargo bed falls accidentally Before closing the cargo bed be sure others are standing away from the utility vehicle and that no one is sitting on the seat Keep hands and fingers away from the space between the car go bed and seat backs UJW410 book Page 7 Monday December 15 2003 4 36 PM ...

Page 62: ...engine performance 1 Spark plug 2 Spark plug cap 1 Check for discoloration and heavy car bon deposits The normal electrode color will be tan If it is not replace it a Spark plug gap 1 2 Specified spark plug BPR2ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in a UJW410 book Page 8 Monday December 15 2003 4 36 PM ...

Page 63: ...al sparks which could lead to explosion or fire Engine oil Checking the engine oil level 1 Place the utility vehicle on a level sur face 2 Lift the seat YXP700 or cargo bed YXP1000 See page 8 6 8 7 for lifting and lowering procedures 3 Remove the dipstick wipe it off with a clean rag and then insert the dipstick back into the dipstick hole Spark plug torque 20 Nm 2 0 m kgf 14 5 ft lbf 1 UJW410 boo...

Page 64: ...evel mark 5 The oil level should be between the max CAUTION Be sure no foreign material enters the crankcase Replacing the engine oil 1 Place the utility vehicle on a level sur face 2 Place a container under the engine 3 Remove the engine oil filler cap and en gine oil drain bolt to drain the oil MIN MAX 1 2 3 1 UJW410 book Page 10 Monday December 15 2003 4 36 PM ...

Page 65: ... an oil collection station 4 Install the drain bolt along with a new drain bolt gasket and then tighten it to the specified torque 5 Add the specified amount of engine oil and then install the oil filler cap CAUTION Be sure no foreign material enters the crankcase Tightening torque Drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended oil See page 10 3 Oil change quantity 0 9 L 0 79 Imp qt 0 95 US qt U...

Page 66: ...ter element cleaning To remove the air filter elements 1 Unlatch the air filter cover holders and re move cover 2 Lift the air filter element and pre air filter element out of the air filter case 1 Air filter element 2 Pre air filter element CAUTION Be careful not to drop anything into the air inlet 1 1 1 2 1 2 UJW410 book Page 12 Monday December 15 2003 4 36 PM ...

Page 67: ...ON Do not wring out the pre air filter element this could cause it to tear CAUTION Do not attempt to clean the air filter ele ment with compressed air It could be damaged 5 To replace the elements reverse the above steps CAUTION The UP mark on the pre air filter element should face up 1 2 UJW410 book Page 13 Monday December 15 2003 4 36 PM ...

Page 68: ...ary sheave clockwise and the drive belt will roll off the sheave Inspection To inspect the drive belt check for frayed edges or tears and measure the drive belt as shown If the belt shows excessive wear or damage or if it reaches the wear limit of 27 9 mm 1 10 in replace the belt with a new one a Wear limit 5 To install the drive belt reverse the Y 60 a UJW410 book Page 14 Monday December 15 2003 ...

Page 69: ... Follow with milk of magnesia beaten egg or vegetable oil Call physi cian immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in en The battery doesn t require the addition of wa ter If the battery loses its charge have an ex perienced mechanic charge it UJW410 boo...

Page 70: ...ure to use the specified fuse Using a wrong fuse can cause electrical system damage and create a fire hazard CAUTION When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting 1 Main fuse 2 Auxiliary DC jack fuse 3 Headlight signaling system fuse Replacement Fuse Main fuse 20 A Headlight signaling system fuse 10 A Auxiliary DC jack fuse 10 A 1 2 3 UJW410 boo...

Page 71: ...k the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommend 1 Transmission oil plug CAUTION Be sure no foreign material enters the transmission case 3 Install the transmission oil filler plug Recommended oil SAE 90 gear oil 1 UJW410 book Page 17 Monday December 15 2003 4 36 PM ...

Page 72: ...acement consult a Yamaha dealer Wheel removal To remove and install a wheel on your utility vehicle 1 Nut 4 1 With the wheels blocked to prevent the utility vehicle from moving loosen the wheel nuts 2 Elevate the utility vehicle with a jack and 1 1 UJW410 book Page 18 Monday December 15 2003 4 36 PM ...

Page 73: ...de towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 1 Tapered nut 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 80 Nm 8 0 m kgf 58 ft lbf Rear 80 Nm 8 0 m kgf 58 ft lbf UJW410 book Page 19 Monday December 15 2003 4 36 PM ...

Page 74: ...a dealer before using your utility vehicle if you suspect brake problems Brake failure could result in a serious accident Brake pedal free play adjustment CAUTION Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the service lid from the floor of the utility vehicle Y 61a UJW410 book Page 20 Monday Decem...

Page 75: ...free play distance needs adjusting loosen the locknut and turn the adjusting nut in or out in 180 increments only due to the cam shape of adjuster until the free play specification is met Then tighten the locknut to the specified torque Brake pedal free play 20 25 mm 0 79 0 98 in 7 18 17 16 15 14 13 12 11 10 9 8 a 1 2 1 2 YXP700 UJW410 book Page 21 Monday December 15 2003 4 36 PM ...

Page 76: ...dlight bulb If a headlight bulb burns out replace it as fol lows 1 Remove the headlight bulb holder by turning it counterclockwise 1 Headlight bulb holder 2 Remove the defective bulb by unhooking the headlight bulb holder tabs Tightening torque 17 N m 1 7 m kgf 12 ft lbf YXP1000 UJW410 book Page 22 Monday December 15 2003 4 36 PM ...

Page 77: ...s 4 Install the headlight bulb holder by turn ing it clockwise Adjusting a headlight beam CAUTION It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b UJW410 book Page 23 Monday December 15 2003 4 36 PM ...

Page 78: ...Replacing a taillight bulb If a taillight bulb burns out have a Yamaha dealer replace it UJW410 book Page 24 Monday December 15 2003 4 36 PM ...

Page 79: ... 2 Drain the carburetor float chamber into a clean container by loosening the drain NOTE Use of fuel stabilizer and conditioner elimi nates the need to drain the fuel system Con sult a Yamaha dealer if the fuel system needs to be drained instead Engine preparation 1 With the key removed and the spark plug lead disconnected turn the clutch by hand until compression is felt This puts the valves in t...

Page 80: ...ttery from the utility vehi cle and store it in a cool dry place that stays between 0 C 32 F and 30 C 90 F 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid dam age NOTE Batteries like the one supplied with your vehi cle normally do not require you to check the water level inside the battery for the one year warranty period provi...

Page 81: ... 1289 mm 50 7 in YXP1000 Overall height steering height 1275 mm 50 2 in YXP700 1353 mm 53 3 in YXP1000 Height of floor 391 mm 15 4 in YXP700 463 mm 18 2 in YXP1000 Wheelbase 1637 mm 64 4 in YXP700 1939 mm 76 3 in YXP1000 Tread Front 940 mm 37 0 in YXP700 1029 mm 40 5 in YXP1000 Rear 980 mm 38 6 in YXP700 1029 mm 40 5 in YXP1000 UJW410 book Page 1 Monday December 15 2003 4 36 PM ...

Page 82: ...2 persons Engine Engine type Air cooled 4 stroke OHV Cylinder arrangement Forward inclined single cylinder Displacement 357 cm3 Bore x stroke 85 x 63 mm 3 30 x 2 48 in Compression ratio 8 0 1 Starting system Electric starter Ignition system TCI Magneto Spark plug type manufacturer BPR2ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Model YXP700 YXP1000 UJW410 book Page 2 Monday December 15 2003 4 ...

Page 83: ...qt Transmission Type V belt automatic centrifugal V belt width and outer line length 31 x 1010 mm 1 22 x 39 76 in V belt wear limit 27 9 mm 1 10 in Transmission oil Type SAE 90 gear oil Quantity 0 42 L 0 37 Imp qt 0 44 US qt Steering system Type Rack and pinion YXP700 Worm and pin YXP1000 Model YXP700 YXP1000 UJW410 book Page 3 Monday December 15 2003 4 36 PM ...

Page 84: ... self adjusting Brake pedal freeplay linkage adjustment 20 25 mm 0 79 0 98 in Parking brake Type Foot type with automatic release Wheel Tire size Front 20 x 10 8 4 PLY YXP700 22 x 11 10 6 PLY YXP1000 Rear 20 x 10 8 4 PLY YXP700 22 x 11 10 6 PLY YXP1000 Tire pressure Front 70 84 kPa 0 70 0 84 kgf cm2 10 12 psi Rear 70 84 kPa 0 70 0 84 kgf cm2 10 12 psi Model YXP700 YXP1000 UJW410 book Page 4 Monday...

Page 85: ...W 2 Taillight Sealed beam 2 Indicator light Engine oil level warning light 12 V 3 4 W 1 Specified fuses Main fuse 20 A Headlight signaling system fuse 10 A Auxiliary DC jack fuse 10 A Model YXP700 YXP1000 UJW410 book Page 5 Monday December 15 2003 4 36 PM ...

Page 86: ...u that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 160 100 20 6 1 000 600 125 12 2 000 1 200 250 18 3 000 1 800 375 24 4 000 2 400 500 30 5 000 3 000 625 36 6 000 3 600 750 42 7 000 4 200 875 48 8 000 4 800 1 000 54 9 000 5 400 1 125 UJW410 book Page 1 Mond...

Page 87: ...by Side vehicle be inspected and registered for warranty by an authorized Yamaha Side by Side Vehicle dealer In order for this warranty to remain in effect this YAMAHA MOTOR CORPORATION U S A MAKES NOOTHERWARRANTYOFANYKIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HERE...

Page 88: ...YAMAHA EXTENDED SERVICE Y E S UJW410 book Page 1 Monday December 15 2003 4 36 PM ...

Page 89: ...1 2 3 4 5 6 7 8 9 10 11 12 13 UJW410 book Page 2 Monday December 15 2003 4 36 PM ...

Page 90: ...B6 fm Page 1 Monday June 18 2001 11 18 AM ...

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