Yamaha YX10ZPSG Owner'S Manual Download

Page: 141 / 198

8-28

8. Park the vehicle on a level surface, stop

the engine, and then check the transmis-
sion case for oil leakage.

TIP

If oil is leaking confirm that the transmission
oil filler cap is properly installed and then have
a Yamaha dealer check the transmission.

9. Check the transmission oil level and cor-

rect if necessary.

10. Install the panel.

EBU32370

Final gear oil

Checking the final gear oil level

1. Park the vehicle on a level surface.
2. Remove the final gear oil filler bolt and its

gasket, and then check the oil level in the
final gear case. The oil level should be at
the brim of the filler hole.

3. If the oil is below the brim of the filler hole,

add sufficient oil of the recommended
type to raise it to the correct level.

NOTICE:

Be sure no foreign material

enters the final gear case.

[ECB00422]

4. Check the gasket for damage, and re-

place it if necessary.

5. Install the oil filler bolt and its gasket, and

then tighten the bolt to the specified
torque.

1. Final gear oil
2. Gasket
3. Final gear oil filler bolt
4. Correct oil level

U2HC70E0.book Page 28 Monday, August 17, 2015 11:59 AM

Summary of Contents for YX10ZPSG

Page 1: ...DIC183 2HC F8199 70 YX10ZPSG OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...EBU33110 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold U2HC70E0 book Page 1 Monday August 17 2015 11 59 AM ...

Page 3: ...the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any ques tions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING EWB03490 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 ...

Page 4: ...afety alert symbol It is used to alert you to poten tial personal injury hazards Obey all safety messages that fol low this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key inform...

Page 5: ...n road use 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 This vehicle complies with all provinces off highway noise level and spark arrester laws and regulations EBU33130 YX10ZPSG OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition July 2015 All rights reserved An...

Page 6: ...5 Reverse gear lock lever REV 4 16 Accelerator pedal 4 16 Clutch pedal 4 17 Brake pedal 4 17 Parking brake lever 4 18 Shift lever 4 19 Fuel tank cap 4 19 Doors 4 20 Seats 4 20 Adjusting the driver seat position 4 22 Adjusting the steering wheel position 4 22 Seat belts 4 23 Glove compartment 4 23 Storage compartments 4 24 Cup holders 4 26 Cargo bed 4 27 Flag pole bracket 4 28 Adjusting the front s...

Page 7: ...TION 6 1 Engine break in 6 1 Starting the engine 6 2 Shift lever operation and reverse driving 6 3 Selecting the drive mode 6 7 Parking 6 9 Loading 6 9 BASIC GUIDE FOR SAFE USE 7 1 KNOW YOUR VEHICLE 7 1 LEARNING TO OPERATE YOUR VEHICLE 7 12 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 4 General maintenance and ...

Page 8: ...rake lever free play adjustment 8 48 Brake light switch adjustment 8 49 Cable inspection and lubrication 8 49 Pedal lubrication 8 49 Checking the stabilizer bushes 8 50 Upper and lower arm pivot lubrication left and right 8 51 Rear knuckle upper and lower pivot lubrication left and right 8 51 Drive shaft universal joint lubrication 8 52 Steering shaft lubrication 8 52 Wheel removal 8 53 Checking a...

Page 9: ...Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification number records 11 1 YAMAHA SIDE BY SIDE OFF ROAD VEHICLE WARRANTY POLICY 11 4 INDEX 12 1 U2HC70E0 book Page 4 Monday August 17 2015 11 59 AM ...

Page 10: ...1 1 1 EBU31130 LOCATION OF THE WARNING AND SPECIFICATION LABELS 3 1 2 4 5 6 5 6 8 15 3 10 11 3 17 16 7 14 9 3 13 12 18 21 20 19 U2HC70E0 book Page 1 Monday August 17 2015 11 59 AM ...

Page 11: ...1 2 1 23 24 22 27 26 25 U2HC70E0 book Page 2 Monday August 17 2015 11 59 AM ...

Page 12: ...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 replacement label is available from your Yamaha dealer U2HC70E0 book Page 3 Monday August 17 2015 11 59 AM ...

Page 13: ...explosion Read owner s manual for instructions Do not incinerate puncture or open Cette unité contient de l azote à haute pression Une mauvaise manipulation peut entraîner d explosion Voir le manuel d utilisateur pour les instructions Ne pas brûler ni perforer ni ouvrir 1HP F2259 11 1 2 3 U2HC70E0 book Page 4 Monday August 17 2015 11 59 AM ...

Page 14: ...ns et bras dans l habitacle et agripper le volant ou la poignée de maintien Any part of your body arms legs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the steering wheel Do not try to stop a vehicle tipover using your arm or leg 5B4 K7761 00 WARNING YAMAHA 1XD K8483 ...

Page 15: ...ant Répartir le poids de la charge de façon équilibrée et le plus bas possible dans la caisse une charge mal équilibrée augmente le risque de capotage Le mauvais usage de la caisse de chargement ou de l arceau de protection peut provoquer de graves blessures ou la mort par suite d une perte de contrôle d un capotage ou d un accident quelconque Aucun passager dans la caisse de chargement YAMAHA 1XD...

Page 16: ...La charge du véhicule comprend le poids du pilote du passager des accessoires et la charge Ne pas dépasser la charge maxmale du véhicule Poids nominal brut du véhicule 1025 kg 2260 lbs maximum véhicule poids du pilote du passager des accessoires et charge PRESSION DE SERVICE DES PNEUS Régler les pneus à froid AVERTISSEMENT La charge ne doit pas exéder 4 5 kg 10 lbs Les vapeurs d essence peuvent pr...

Page 17: ...um Vehicle Load 719 lbs 326 kg Never carry passengers in cargo bed YAMAHA 2HC F1696 12 WARNING Improper tire pressure or overloading this vehicle may cause severe injury or death from loss of control or rollover Never set or allow tire pressure to be below the minimum Tire may dislodge from rim VEHICLE LOAD of 0 kg 0 lb 195 kg 430 lbs Recommended FRONT REAR Minimum FRONT REAR 114 kPa 128 kPa 110 k...

Page 18: ... et agripper le volant ou la poignée de maintien Ne jamais agripper l arceau de protection Ne jamais tenter d empê cher un capotage à l aide du bras ou de la jambe YAMAHA MOTOR CANADA LTD 480 Gordon Baker Road Toronto Ontario M2H 3B4 Canada 1XD F4162 00 The original equipment overhead structure on this vehicle meets US OSHA and ISO 3471 requirements for rollover protection structures m 700Kg for I...

Page 19: ...hway Vehicles ANSI ROHVA 1 2011 Standard Date of manufacture 1XD F4161 00 YAMAHA certifie que ce véhicule hors route est conforme à la norme ANSI ROHVA 1 2011 de l ANSI intitulée American National Standard for Recreational Off Highway Vehicles Date de fabrication 1XD F4161 10 WARNING AVERTISSEMENT Moving parts can crush and cut Do not operate engine with guard removed 2HC 77762 00 Les pièces mobil...

Page 20: ...ding across slopes Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid hard acceleration when turning even from a stop Slow down before entering a turn Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Avoid loss of control and rollovers Do not put any par t of your body outside of the vehicle for any reason Keep ...

Page 21: ...e alors que leurs pieds reposent à plat sur le plancher et qu ils sont assis le dos contre le dossier du siège Demeurer entièrement dans l habitacle du véhicule Conduire de façon responsable Prévenir la perte de contrôle ou les roulades Éviter les manœuvres subites glissements latéraux dérapages queues de poisson et zigzags ne jamais tenter d acrobaties Ralentir avant d entamer un virage Éviter d ...

Page 22: ...se two chapters and the labels on the vehicle to instruct new operators and passengers Do not allow anyone else to operate your vehicle or ride as a passenger if you are unsure whether he or she is willing and able to follow these instructions Get to know your vehicle This off road vehicle will handle and maneuver differently from cars ATVs go carts golf cars and grounds keeping vehicles Follow th...

Page 23: ...roperly Both driver and passenger must be able to put both feet flat on the floorboard while seated upright with their backs against the backrests Passenger must be able to reach and hold the passenger handhold in front of them Both driver and passenger should wear an approved motorcycle helmet that fits properly Both driver and passenger should also wear eye protection goggles or a face shield gl...

Page 24: ...efore loading the cargo bed Do not overload the vehicle or cargo bed Refer to the labels on the vehicle for specific loading limits and recommended tire air pressure Keep heavier objects and the load in general centered side to side and as low and as far for ward in the cargo bed as possible Secure cargo so that it will not shift a loose load could change handling unexpectedly or be thrown forward...

Page 25: ...rds that could enter the vehicle Abrupt maneuvers or aggressive driving even on flat open areas can cause loss of control including rollovers The YXZ1000R has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some other vehicles may not Avoid rollovers Use care when turning Turning the steering wheel too far or too fast can result ...

Page 26: ... vehicle may tip or roll keep your body completely inside the protec tive structure of the vehicle Brace yourself by pressing your feet firmly on the floorboard and keep a firm grip on the steering wheel or passenger handhold Do not put your hands or feet outside of the vehicle for any reason Your arm or leg could be crushed Do not try to stop a vehicle tipover using your arm or leg Do not operate...

Page 27: ...noxide can cause headaches dizziness drowsiness nausea confusion and eventually death Carbon monoxide is a colorless odorless tasteless gas which may be present even if you do not see or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in enclo...

Page 28: ...can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket parts accessories and modifications While you may find aftermarket products similar in design and quality to genuine Yamaha Acces sories recognize that some aftermarket accessories or modifications are not suit...

Page 29: ...ch the performance ca pabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate Refer to page 8 54 for tire specifications and more information on replacing your tires U2HC70E0 book Page 8 Monday August 17 2015 11 59 AM ...

Page 30: ...3 4 5 6 10 11 7 8 9 1 Front shock absorber 2 Brake fluid reservoir 3 Clutch fluid reservoir 4 Door 5 Shoulder bolster 6 Driver seat belt 7 Cargo bed 8 Muffler 9 Exhaust pipe 10 Engine 11 Transmission U2HC70E0 book Page 1 Monday August 17 2015 11 59 AM ...

Page 31: ...ght view 1 2 3 7 8 4 5 6 9 1 Rear shock absorber 2 Engine oil tank 3 Air filter 4 Passenger seat belt 5 Battery 6 Fuses 7 Coolant reservoir 8 Headlight 9 Fuel tank cap U2HC70E0 book Page 2 Monday August 17 2015 11 59 AM ...

Page 32: ... 10 8 9 13 11 14 1 Steering wheel 2 Reverse gear lock lever 3 Multi function meter unit 4 Main switch 5 Shift lever 6 Parking brake lever 7 Passenger handhold 8 Helmet indicator light 9 Seat belt indicator light 10 Light switch 11 On Command drive knob 12 Accelerator pedal 13 Brake pedal 14 Clutch pedal U2HC70E0 book Page 3 Monday August 17 2015 11 59 AM ...

Page 33: ...not be removed TIP The helmet indicator light comes on and stays on while the key is turned to on EBU31240 off All electrical circuits are switched off The key can be removed EBU31250 start The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts 1 Main switch 2 off 3 on 4 start 1 2 3 4 U2HC70E0 book Page 1 Monday August 17 2015 11 59 A...

Page 34: ... is in the reverse position 1 Shift timing indicator light 2 Electric Power Steering warning light EPS 3 Differential gear lock indicator light DIFF LOCK 4 Parking brake indicator light P 5 Reverse indicator light R 6 Neutral indicator light N 7 Engine trouble warning light 8 Coolant temperature warning light 9 Drivetrain icon 1 2 3 4 5 6 7 8 9 1 Helmet indicator light 2 Seat belt indicator light ...

Page 35: ...ronizing mechanism in the differential gear case the drivetrain icon may not come on until the vehicle starts moving When the On Command drive knob is set to DIFF LOCK or 4WD the drivetrain icon and the differential gear lock indicator light will flash until the differential gear is completely locked or unlocked If the icon and the indicator light continue to flash the differential is not complete...

Page 36: ...goes off The vehicle can be operated normally when the warning light is off The warning light comes on in red when the engine is overheating If the red light comes on stop the vehicle as soon as it is safe to do so and allow the engine to idle for about 10 minutes If the warning light does not go off stop the engine and allow it to cool See page 8 66 TIP The coolant temperature warning light can b...

Page 37: ... remains on have a Yamaha dealer check the electrical circuit EBU33041 Electric Power Steering warning light EPS This warning light comes on when the key is turned to on and then goes off once the engine is started If the warning light re mains on or comes on after the engine is started the EPS system may not be working correctly When this occurs have a Yamaha dealer check the EPS system The elect...

Page 38: ...il the driver seat belt is properly latched If the indicator light does not come on when the key is turned to on or if the indicator light remains on after the driver seat belt is properly latched have a Yamaha dealer check the electrical circuit EBU34952 Multi function meter unit The multi function meter unit is equipped with the following speedometer tachometer 1 Tachometer 2 Transmission gear d...

Page 39: ...ng indicator control mode self diagnosis device TIP To switch the display between mph and km h turn the key to off then push and hold the SELECT button while turning the key to on Speedometer The speedometer shows the vehicle s travel ing speed 1 Speedometer 1 U2HC70E0 book Page 7 Monday August 17 2015 11 59 AM ...

Page 40: ...uit NOTICE ECB02920 Do not operate the engine in the tachome ter red zone Red zone 10500 r min and above Odometer and tripmeter modes The odometer shows the total distance trav eled by the vehicle The tripmeters show the distance traveled since they were last reset TIP The odometer will lock at 99999 1 Tachometer 2 Tachometer red zone 1 2 1 Odometer Tripmeter A Tripmeter B 2 SELECT button 3 RESET ...

Page 41: ...E SET button for three seconds The tripme ters can be used to estimate the distance that can be traveled with a full tank of fuel This in formation enables you to plan future fuel stops Clock hour meter and voltage display modes The clock displays time in 12 hour format The hour meter shows the total time the en gine has been running The voltage display shows the battery volt age 1 Clock Hour mete...

Page 42: ... SELECT button and the min ute digits will start flashing 5 Push the RESET button to set the min utes 6 Push the SELECT button and then re lease it to start the clock Voltage display mode This display shows and the battery volt age If the battery voltage is less than 10 volts LO is displayed and if the voltage is above 16 volts HI is displayed NOTICE ECB02050 If the voltage display indicates LO or...

Page 43: ...ashes refuel as soon as possible TIP This fuel meter is equipped with a self diag nosis system If a problem is detected in an electrical circuit all the display segments and fuel level warning indicator start flashing If this occurs have a Yamaha dealer check the electrical circuit Transmission gear display 1 Fuel level warning indicator 2 Fuel meter 1 2 1 Transmission gear display 2 Neutral indic...

Page 44: ...nd the multi function display indicates an error code If the multi function display indicates an error code note the code number and then have a Yamaha dealer check the vehicle NOTICE ECB00812 If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid en gine damage Shift timing indicator light 1 Error code display 2 Engine trouble war...

Page 45: ...t timing indicator light comes on the shift timing indicator light can be adjusted To set the flashing pattern 1 Push the RESET button to select one of the following flashing pattern settings On the indicator light stays on when activated The indicator light will con firm this setting by staying on Flash the indicator light flashes when activated The indicator light will con firm this setting by f...

Page 46: ...int To set the deactivation point TIP The shift timing indicator light deactivation point can be set between 7000 r min and 12000 r min The deactivation point can be set in increments of 500 r min Be sure to set the deactivation point to a higher engine speed than for the activation point otherwise the shift timing indicator light will not come on The tachometer needle will start over at 7000 r mi...

Page 47: ...e battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU31400 On Command drive knob 2WD 4WD DIFF LOCK This vehicle is equipped with an On Com mand drive knob to select the drive mode The knob has three positions 2WD 4WD and DIFF LOCK Select the appropriate drive according to terrain and conditions 1 Light swi...

Page 48: ...prevent the transmission from being acci dently shifted into reverse this model is equipped with a reverse gear lock mecha nism To release the lock and be able to shift the transmission into reverse pull this lever towards you TIP See page 6 5 for information on driving in re verse EBU31411 Accelerator pedal Press the accelerator pedal to increase en gine speed Spring tension returns the pedal to ...

Page 49: ...he clutch release the clutch pedal The clutch pedal should be pressed rapidly and released slowly for smooth clutch operation EBU31420 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Accelerator pedal 1 1 Clutch pedal 1 U2HC70E0 book Page 17 Monday August 17 2015 11 59 AM ...

Page 50: ...ke pull the lever up ward firmly To release the parking brake pull slightly up ward on the lever press the release button and then push the lever all the way down TIP Spring tension helps return the lever to the released position If you drive the vehicle with the parking brake engaged a buzzer will sound 1 Brake pedal 1 1 Release button 2 Parking brake lever 1 2 U2HC70E0 book Page 18 Monday August...

Page 51: ...used in combination with the clutch pedal when shifting See page 6 3 for shift lever operation EBU31450 Fuel tank cap To open Remove the fuel tank cap by turning it coun terclockwise To close Install the fuel tank cap by turning it clock wise 1 Shift lever 1 1 Fuel tank cap 1 U2HC70E0 book Page 19 Monday August 17 2015 11 59 AM ...

Page 52: ...ard until it is securely latched Be sure the door is SE CURELY LATCHED AFTER CLOSING IT TIP When opening a door from the outside use the mark to locate the door handle EBU33461 Seats To remove a seat cushion lift the front of the cushion and then pull the cushion off 1 Door 2 Handle 3 mark 1 3 2 U2HC70E0 book Page 20 Monday August 17 2015 11 59 AM ...

Page 53: ...ront of the cushion into the grommet while pushing the cushion downward Make sure the seats are properly secured before starting off WARNING A loose seat could cause the operator to lose control or cause the operator or passenger to fall EWB03510 1 Driver seat cushion 1 Passenger seat cushion 1 1 U2HC70E0 book Page 21 Monday August 17 2015 11 59 AM ...

Page 54: ... the driver seat position and make sure it is locked in place before starting off EBU35002 Adjusting the steering wheel position The steering wheel position can be adjusted to suit the driver s preference WARNING Never adjust the steering wheel position while operating the vehicle otherwise the steering wheel may suddenly change posi tion which may lead to an accident EWB04000 To adjust the steeri...

Page 55: ...e See page 7 5 for more information EBU31501 Glove compartment This vehicle is equipped with a glove com partment When storing any documents in the glove compartment be sure to wrap them in a plas tic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the glove compartment 1 Steering wheel position adjusting lever 1 1 Seat belt 1 1 U2HC70E0 book Page 2...

Page 56: ...iate cushioning material EBU35010 Storage compartments There are storage compartments located in the center console under the passenger seat and behind the driver seat To access the storage compartment under the passenger seat remove the seat cushion see page 4 20 for more information 1 Unlock 2 Open 1 2 1 Storage compartment 1 U2HC70E0 book Page 24 Monday August 17 2015 11 59 AM ...

Page 57: ...void injury or death never store fuel or flammable liq uids in this storage compartment EWB03230 NOTICE Do not exceed the specified max imum load limit for this storage compart ment ECB02090 1 Storage compartment 1 Storage compartment 1 1 Maximum load limit Storage compartment behind driver seat 4 5 kg 10 lb U2HC70E0 book Page 25 Monday August 17 2015 11 59 AM ...

Page 58: ...ap them in appro priate cushioning material EBU31520 Cup holders Be sure to tightly close the cap of any plastic bottle before placing it in a cup holder Some plastic bottles may not fit into the cup holders depending on their size and shape WARNING EWB03240 Never ride with any open or glass con tainers in the cup holders otherwise the contents may spill and the glass contain ers may be thrown abo...

Page 59: ...35020 Cargo bed WARNING EWB03250 Never carry passengers in the cargo bed Do not exceed the specified maximum load limits Heavier cargo could cause loss of control because of improper weight balance There are four cargo hooks in the cargo bed For additional loading information see page 6 9 1 Cup holder 1 1 Cargo hook Maximum load limit 136 0 kg 300 lb 1 1 U2HC70E0 book Page 27 Monday August 17 2015...

Page 60: ... low speed compression damping force adjusting screw WARNING EWB02492 Suspension components become hot during operation Never touch the com pression damping force adjusting bolt and screw the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled Always adjust the shock absorber as semblies on the left and right side to the sa...

Page 61: ... it would be advisable to check the number of clicks or turns of each damping force adjusting mechanism and to modify the specifications as necessary Spring preload 1 Loosen the locknut 2 Turn the spring preload adjusting nut in direction a to increase the spring pre load and thereby harden the suspension and in direction b to decrease the spring preload and thereby soften the suspen sion TIP A sp...

Page 62: ...ten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00082 Spring preload setting Minimum soft Distance A 428 2 mm 16 86 in Standard Distance A 415 5 mm 16 36 in Maximum hard Distance A 402 8 mm 15 86 in 1 Distance A Tightening torque Locknut 41 Nm 4 1 m kgf 30 ft lbf 1 U2HC70E0 book Page 30 Monday August...

Page 63: ...force and thereby harden the high speed compres sion damping turn the compression damping force adjusting bolt in direction a To de crease the compression damping force and thereby soften the high speed compression damping turn the adjusting bolt in direction b 1 Rebound damping force adjusting screw 1 a b Rebound damping setting Minimum soft 26 click s in direction b Standard 12 click s in direct...

Page 64: ...eby soften the low speed compression damping turn the adjusting screw in direction b 1 High speed compression damping force adjusting bolt High speed compression damping setting Minimum soft 4 turn s out from the fully turned in posi tion Standard 2 turn s out from the fully turned in posi tion Maximum hard Adjusting bolt fully turned in 1 a b 1 Low speed compression damping force adjusting screw ...

Page 65: ...elf Take the shock absorber assembly to a Yamaha dealer for any service EBU35041 Adjusting the rear shock absorber as semblies The rear shock absorber assemblies are equipped with a spring preload adjusting nut a rebound damping force adjusting screw a high speed compression damping force ad justing bolt and a low speed compression damping force adjusting screw WARNING EWB02492 Suspension componen...

Page 66: ...sting mechanism may not exactly match the following specifications due to small differences in production the ac tual number of clicks or turns always repre sents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks or turns of each damping force adjusting mechanism and to modify the specifications as necessary Spring preload 1 Loosen the lo...

Page 67: ... lower the spring preload 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00082 1 Locknut 2 Spring preload adjusting nut 3 Special wrench 1 3 2 a b Spring preload setting Minimum soft Distance A 496 8 mm 19 56 in Standard Distance A 484 1 mm 19 06 in Maximum hard Distance A 471 4 mm 18 56 in 1 ...

Page 68: ...the high speed compres sion damping turn the compression damping force adjusting bolt in direction a To de crease the compression damping force and thereby soften the high speed compression damping turn the adjusting bolt in direction b Tightening torque Locknut 41 Nm 4 1 m kgf 30 ft lbf 1 Rebound damping force adjusting screw 1 a b Rebound damping setting Minimum soft 26 click s in direction b St...

Page 69: ...y soften the low speed compression damping turn the adjusting screw in direction b 1 High speed compression damping force adjusting bolt High speed compression damping setting Minimum soft 4 turn s out from the fully turned in posi tion Standard 1 1 2 turn s out from the fully turned in position Maximum hard Adjusting bolt fully turned in 1 a b 1 Low speed compression damping force adjusting screw...

Page 70: ... assembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EBU35051 Auxiliary DC jack The auxiliary DC jack is located at the left side of the glove compartment The auxiliary DC jack can be used for suitable work lights ra dios etc The auxiliary DC jack should only be used when the engine is running and the lights are turned off NOTICE ECB02250 Do not use accessories re...

Page 71: ...ight switch to 2 Turn the accessory off 3 Start the engine See page 6 2 4 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap 1 Auxiliary DC jack cap 2 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 10 A 120 W 2 1 U2HC70E0 book Page 39 Monday Au...

Page 72: ...nd any problem If a problem can not be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Brakes Check operation free play fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary 5 3 8 42 8 49 Clutch Check operation free play fluid level and fluid leakage Fill with D...

Page 73: ...n 5 7 Seat belts Check for proper operation and belt wear 5 8 Passenger handhold Check for stability and proper fastening 5 8 7 8 Steering Check for proper operation 5 8 Shift lever Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 9 Instruments lights and switches Check operation and correct if necessary 5 9 8 62 8 62 Wheels and tires Check tire pressure and...

Page 74: ... fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a Yamaha dealer Brake operation Check the operation of the brakes at the start of every ride Test the brakes at slow speed after starting out to make sure they are work ing properly If the brakes do not provide proper braking performance...

Page 75: ...ueling turn off the engine and be sure that no one is sitting in the vehi cle Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dry ers 2 Do not overfill the fuel tank Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up ...

Page 76: ...ot recom mended by Yamaha because it may cause fuel system damage or vehicle performance problems Portable fuel containers If you carry a portable fuel container in the bed of your Yamaha YXZ1000R be sure to secure it with the cap tightened before driving the vehicle Always place a portable fuel container on the ground before filling it Before removing the container cap touch the container with th...

Page 77: ... clutch slippage do not mix any chemical additives EBU31760 Coolant Check the coolant level in the coolant reser voir when the engine is cold the coolant level will vary with engine temperature The coolant level is satisfactory if it is be tween the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additional coolant to bring th...

Page 78: ...ed EBU31780 Differential gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See page 8 30 for details EBU31790 Accelerator pedal Check to see that the accelerator pedal oper ates correctly It must operate smoothly and spring back to the idle position fully when re leased Have a Yamaha dealer repair as nec essary for proper operation Coolant reservoir capaci...

Page 79: ...lp make sure your restraint systems are working properly after a crash have them in spected and any necessary replacements made as soon as possible EBU31810 Passenger handhold Check that the handhold bar and its supports are in good condition Confirm that the lock ing pins are securely fastened and then push and pull on the handhold to make sure that it is not loose EBU31820 Steering Park on level...

Page 80: ...g off WARNING Control cables can freeze in cold weather and you could be unable to control the vehicle EWB03280 EBU35331 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the tire pressure gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Operat...

Page 81: ...si Vehicle load 195 kg maximum 430 lb maximum Front 114 0 kPa 1 140 kgf cm 16 5 psi Rear 169 0 kPa 1 690 kgf cm 24 5 psi Minimum tire pressure Vehicle load 0 195 kg 0 430 lb Front 110 0 kPa 1 100 kgf cm 16 0 psi Rear 124 0 kPa 1 240 kgf cm 18 0 psi Vehicle load 195 kg maximum 430 lb maximum Front 110 0 kPa 1 100 kgf cm 16 0 psi Rear 165 0 kPa 1 650 kgf cm 24 0 psi Maximum vehicle load 326 0 kg 719...

Page 82: ...5 11 5 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 1 Tire wear limit 1 U2HC70E0 book Page 11 Monday August 17 2015 11 59 AM ...

Page 83: ...us parts in the engine wear and polish them selves to achieve the correct operating clear ances During this period prolonged full throttle op eration or any condition that might result in excessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a subst...

Page 84: ...ral indicator light should come on The engine can be started in any gear if the clutch pedal is applied However it is recommended to shift into neutral before starting the engine 4 With your foot off the accelerator pedal start the engine by turning the key to start If the engine fails to start release the key and then try starting it again Wait a few seconds before the next attempt Each attempt s...

Page 85: ...elerator pedal apply the clutch and then repeatedly move the shift lever forward until it stops When it stops it will be in first gear Move the shift lever rearward slightly to reach the neu tral position and then release the clutch NOTICE ECB03040 Even with the transmission in the neutral position do not coast for long periods of time with the engine off The transmis sion is properly lubricated o...

Page 86: ... gears have properly engaged 4 Release the brake pedal 5 Press the accelerator pedal gradually and at the same time release the clutch pedal slowly 6 Once the vehicle has attained adequate speed release the accelerator pedal and at the same time quickly press the clutch pedal 7 Shift the transmission into second gear Make sure not to shift the transmission into neutral 8 Press the accelerator peda...

Page 87: ...ation and deceleration are shown in the ta ble below To drive in reverse WARNING EWB03300 Before you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Hitting an obstacle or person could result in serious injury or death 1 Stop the vehicle and continue to apply the brake pedal 2 Check behind you 3 Press the clutch pedal and pull the re ve...

Page 88: ...lever and the parking brake if applied 6 Check behind you and then release the brake pedal 7 Press the accelerator pedal gradually and release the clutch pedal slowly Continue to watch to the rear while driving in re verse 1 Reverse gear lock lever REV 1 Shift lever 2 Reverse gear 1 1 2 R 1 N 2 3 4 5 U2HC70E0 book Page 6 Monday August 17 2015 11 59 AM ...

Page 89: ...ed drive mode The drive mode icon and the DIFF LOCK indi cator light come on as follows Knob position Indication Drive mode none 2WD two wheel drive Drive power is supplied to the rear wheels only 4WD four wheel drive Drive power is supplied to the front and rear wheels DIFF LOCK four wheel drive with the differential gear locked Drive power is supplied to the front and rear wheels and the differe...

Page 90: ...rential gear is completely locked or unlocked Turning the steering wheel back and forth will help the differential gear lock to engage or dis engage To protect the drivetrain from damage vehicle speed is limited until the differential gear lock has properly transitioned U2HC70E0 book Page 8 Monday August 17 2015 11 59 AM ...

Page 91: ...the risk of loss of control an overturn or other accident Do not pull objects other vehicles or tow a trailer this vehicle is not de signed for such operation Keep weight in the cargo bed centered side to side and as low and as far for ward as possible Top heavy loads in crease the risk of overturn Make sure that cargo is securely fas tened down a loose load could change handling unexpectedly or s...

Page 92: ...t EBU35751 KNOW YOUR VEHICLE This off road vehicle will handle and maneu ver differently from cars ATVs go carts golf cars and grounds keeping vehicles The YXZ1000R has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some vehicles may not This would include vehicles made primarily for pavement roads improved paths or grounds keep...

Page 93: ...be able to place both feet flat on the floorboard while seated upright with his her back against the backrest Do not drive after using drugs or alcohol Remove the ignition key when the vehicle is not in use to prevent unauthorized use of the machine Parents Many provinces have implemented new mo tor vehicle licensing requirements for young drivers These requirements are in response to the dispropo...

Page 94: ... carry any other passengers Do not car ry passengers in the cargo bed Do not allow someone to ride as a passen ger who has been using drugs or alcohol Do not allow children who need child safety seats or booster seats in the YXZ1000R The seat belt is not designed to restrain au tomotive child safety seats Occupant protection system WARNING EWB03350 Do not make changes to the occupant pro tection s...

Page 95: ...l not protect occupants in all rollovers or accidents Body parts outside of vehicle can be struck by passing objects or crushed during vehicle rollover Do not put your hands or feet outside of the vehicle for any reason Do not hold onto the door cage frame or shoulder bolster Wear your seat belt and helmet If you think or feel that the vehicle may tip or roll do not put your hands or feet outside ...

Page 96: ...ng operation You may also fall completely out or be partial ly ejected from the vehicle which may lead to being crushed between the ground and the vehicle Wearing the seat belt helps you re main in the vehicle the doors and passenger handhold are not a substitute for using a seat belt A crash can damage the restraint systems in your vehicle A damaged restraint system may not properly protect the p...

Page 97: ...ds together along its long edges in order to more eas ily adjust its location up or down along the length of the belt 3 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 4 Put the lap portion of the belt low on your hips Pull up on the shoulder part so the belt is snug across your hips Be sure the seat belt is not caught on the shoulder bolst...

Page 98: ...lot 7 To release the buckle firmly press the re lease button Doors The doors are designed to reduce the likeli hood that you will stick your leg out to stop the vehicle from tipping over or for any other reason in a rollover The doors may also re duce intrusion of objects into the occupant area Make sure the door is securely latched before operation Do not place your arm or hand on the door during...

Page 99: ...lihood that the pas senger puts a hand outside the vehicle if the vehicle begins to tip The driver should make sure the passenger is holding onto the handhold with both hands before operating the vehicle Adjusting the handhold position The handhold can be adjusted to one of three positions to suit the passenger s preference U2HC70E0 book Page 8 Monday August 17 2015 11 59 AM ...

Page 100: ...he holes in the handhold bar with the holes in the handhold supports 3 Insert the pins into the holes and secure them with the wire loops Make sure that the handhold is properly secured before riding 1 Passenger handhold 2 Locking pin 1 2 1 Handhold support 2 Handhold bar 2 1 1 U2HC70E0 book Page 9 Monday August 17 2015 11 59 AM ...

Page 101: ...e floorboard allows you to brace your feet which helps you keep your body in the vehicle in the event of an accident or rollover Keep your feet on the floorboard during operation Steering wheel Keep both hands on the steering wheel ex pect when using your right hand to operate the shift lever Do not hold the steering wheel with your thumbs inside the rim Keep your palms on the outside of the steer...

Page 102: ...e hicle respond to the obstacle This quick motion could injure your thumbs or wrist if your thumbs or hand s are inside the steering wheel Grip the steering wheel so that your thumbs will not be hit by the spokes As an example see the illustration CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE U2HC70E0 book Page 11 Monday August 17 2015 11 59 AM ...

Page 103: ...juries if any part of you is outside the vehicle or protective structure during a rollover Help protect you if outside objects intrude inside the vehicle during operation Help protect you in the event of impact with an obstacle or other vehicle Wear eye protection when operating or riding the vehicle to reduce the risk of a serious ac cident or injury Eye protection such as a face shield or goggle...

Page 104: ... higher speeds until you are thoroughly familiar with the operation and handling of the vehicle Remember driv ing aggressively or making abrupt maneuvers even on flat open areas can cause side roll overs Become familiar with the way the vehicle han dles in the various drive modes Start off with two wheel drive 2WD then four wheel drive 4WD and finally four wheel drive with the differential locked ...

Page 105: ...rol and avoid rollover For example if you feel the back of the vehicle start to slide to your right steer to the right If you think or feel that the vehicle may tip or roll keep your body completely inside the protective structure of the vehicle Brace yourself by pressing your feet firmly on the floorboard and keep a firm grip on the steering wheel or passenger handhold Do not put your hands or fe...

Page 106: ...celerator and allow the drivetrain and engine to absorb vehicle speed Downshift as necessary Ap plication of the brakes provides additional stopping power Leaving the vehicle Do not get out of the vehicle while the engine is running Take the key with when you leave the vehicle There is a serious risk of injury or death because Children or other unauthorized persons may attempt to operate the vehic...

Page 107: ...he brake pedal 2 Switch the drive mode to DIFF LOCK and shift into first gear when parking up hill or reverse gear when parking down hill TIP You may need to turn the steering wheel left and right or release the clutch slightly to help the differential lock into place 3 Stop the engine turn the key to off 4 With the brake pedal still being applied set the parking brake 5 Finally get out of the veh...

Page 108: ... Your Yamaha YXZ1000R has higher ground clearance and other features to handle rug ged terrain and as a result can overturn in situations where some vehicles may not Abrupt maneuvers or aggressive driving can cause loss of control including rollovers even on flat open areas These rollovers can result in crushed limbs and other serious inju ries or death to drivers or passengers When operating the ...

Page 109: ...first on gentle slopes before at tempting steeper hills Always check the terrain carefully before attempting any hill To climb a hill you need traction momentum and steady throttle For more traction and control for climbing steeper and or rougher slopes shift into low gear and select 4WD or DIFF LOCK Travel fast enough to main tain momentum but not so fast that you can not react to changes in the ...

Page 110: ...he brakes which could cause the vehicle to slide If you are sliding or skidding try to steer in the direction the vehicle is sliding to regain con trol For example if you feel the back of the vehicle start to slide to your right steer to the right If you must turn on the hill to avoid an obsta cle do so slowly and carefully If the vehicle starts to tip immediately steer in the downhill direction i...

Page 111: ... To reduce your risk of drowning or other injuries use care when crossing through 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 NOTICE ECB02950 After driving your vehicle in water be sure to drain the trapped water by removing the check hoses at the bottom of the air filter ca...

Page 112: ...To reduce the risk of fire during operation or after leaving the vehicle do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle after operating in areas where combustible materials may have collected Do not idle or park the vehicle in long dry grass or other dry ground cover Encountering obstacles If ...

Page 113: ...tion about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path U2HC70E0 book Page 22 Monday August 17 2015 11 59 AM ...

Page 114: ...hile using the ve hicle If you are not familiar with vehicle service have a Yamaha dealer perform the service WARNING EWB02563 Turn off the engine when performing main tenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire o...

Page 115: ...ice 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 repairs The tools provided in the owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts 1 Owner s manual 1 1 Owner s tool kit 2 Tire pressure gauge 1 2 U2HC70...

Page 116: ... have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the torque settings and adjust them as neces sary U2HC70E0 book Page 3 Monday August 17 2015 11 59 AM ...

Page 117: ...a dealer as they require special tools data and technical skills NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hose for cracks or damage Replace if necessary 2 Valves Check valve clearance Adjust if necessary 3 Spark plugs Check condition Adjust gap and clean Replace if neces...

Page 118: ... induction sys tem Check the air cut off valve reed valve and hose for damage Check condition and clean or replace if nec essary 8 Spark arrester Clean NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U2HC70E0 book Page 5 Monday August 17 2015 11 59 AM ...

Page 119: ... Primary air filter foam Clean Replace if necessary Every 300 600 km 200 400 mi more often in wet or dusty condi tions Secondary air fil ter paper Replace Every 2000 5000 km 1200 3000 mi more often in wet or dusty condi tions 3 Engine oil Change warm engine before draining 4 Engine oil filter cartridge Replace 5 Transmission oil Check oil level and for leakage Change 6 Final gear oil Dif ferential...

Page 120: ...the limit 10 Brake fluid and internals Change the brake fluid Replace internal components of master cyl inder and calipers Every 2 years 11 Brake hoses Replace Every 4 years 12 Accelerator pedal Check operation and free play 13 Reverse lock re lease cable Check operation and adjust or replace if necessary NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 ...

Page 121: ...e Correct if necessary 17 Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary 18 Stabilizer bushes Check for cracks or other damage and re place if necessary 19 Upper and lower arm pivots Lubricate with lithium soap based grease 20 Rear knuckle up per and lower piv ots Lubricate with lithium soap based grease NO ITEM ROUTINE INITIAL EVERY Whichev e...

Page 122: ...ealer at regular intervals replace any damaged or visibly worn part immediately 21 Drive shaft uni versal joint Lubricate with lithium soap based grease 22 Engine mount Check for cracks or damage Check bolt tightness 23 Front and rear axle boots Check for cracks or other damage and re place if necessary 24 Fittings and fas teners Check all chassis fittings and fasteners Correct if necessary NO ITE...

Page 123: ...iginal position and then install the bolts EBU35092 Panels The panels shown need to be removed to perform some of the maintenance jobs de scribed in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed 1 Hood 2 Bolt 1 2 2 U2HC70E0 book Page 10 Monday August 17 2015 11 59 AM ...

Page 124: ...emove the panel Remove the panel by pulling it up as shown To install the panel Place the panel in the original position 1 Panel A 2 Panel B 1 Panel C 1 2 1 1 Panel A 1 U2HC70E0 book Page 11 Monday August 17 2015 11 59 AM ...

Page 125: ...nel A 3 Remove the top cover by removing the quick fastener screw and the bolts 4 Remove the passenger seat cushion See page 4 20 5 Remove the passenger seat by removing the bolts 1 Top cover 2 Bolt 3 Quick fastener screw 2 3 1 U2HC70E0 book Page 12 Monday August 17 2015 11 59 AM ...

Page 126: ...ff as shown To install the panel 1 Place the panel in the original position and then install the bolts and the quick fastener screws 1 Passenger seat 2 Bolt 3 Seat belt 1 3 2 2 1 Panel B 2 Quick fastener screw 3 Bolt 1 2 2 3 2 3 3 U2HC70E0 book Page 13 Monday August 17 2015 11 59 AM ...

Page 127: ...tion 3 Install the passenger seat cushion 4 Install the top cover by installing the bolts and quick fastener screw 5 Install panel A and the hood Panel C To remove the panel Remove the quick fastener screws and then pull the panel off as shown 1 Panel B Tightening torque Passenger seat bolt 32 Nm 3 2 m kgf 23 ft lbf 1 1 Panel C 2 Quick fastener screw 1 2 2 2 U2HC70E0 book Page 14 Monday August 17 ...

Page 128: ...to a nor mal operating temperature the engine oil temperature should reach 60 C 140 F then let the engine idle for a minimum of ten seconds before turning the engine off TIP If the engine is cold take the vehicle for a short drive or let it idle for approximately ten minutes before checking the engine oil level 4 Remove the engine oil tank filler cap and wipe the dipstick with a clean rag 5 Insert...

Page 129: ...C See page 8 10 3 Remove the engine oil tank cover by re moving the bolts 4 Start the engine warm it up for several minutes and then turn it off 5 Place an oil pan or use a trough or funnel beneath the oil tank to collect the used engine oil 6 Remove the engine oil tank filler cap and the cylinder head cap 1 Engine oil tank filler cap 2 Engine oil dipstick 3 Maximum level mark 4 Tip of the engine ...

Page 130: ...8 Place an oil pan under the engine to col lect the used engine oil 9 Remove the engine oil drain bolt and its gasket to drain the oil from the engine 1 Engine oil tank filler cap 1 Cylinder head cap 1 1 1 Engine oil tank drain bolt 2 Gasket 2 1 U2HC70E0 book Page 17 Monday August 17 2015 11 59 AM ...

Page 131: ...nd then install and tighten the en gine oil tank filler cap and the cylinder head cap 12 Start the engine warm it up for several minutes and then turn it off 13 Remove the engine oil tank filler cap and then add sufficient oil of the recommend ed type to raise it to the maximum level mark on the dipstick 1 Engine oil drain bolt 2 Gasket 3 mark 1 2 3 Tightening torques Engine oil drain bolt 10 Nm 1...

Page 132: ...minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 16 Turn the engine off wait at least ten min utes and then check the oil level and cor rect it if necessary 17 Install the engine oil tank cover by install ing the bolts 18 Install the panel To change the engine oil and oil filter 1 Park the vehicle on a level surface 2 Remove the bo...

Page 133: ... remov ing the bolts 4 Remove the bolts and then slide the cen ter bottom panel rearward to remove it 1 Left side panel 2 Right side panel 3 Bolt 3 1 3 2 1 Rear bottom panel 2 Bolt 2 1 2 2 U2HC70E0 book Page 20 Monday August 17 2015 11 59 AM ...

Page 134: ...s removed together with the oil filter car tridge If the O ring remains attached to the crankcase oil leakage may occur TIP An oil filter wrench is available from a Yamaha dealer 7 Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 1 Center bottom panel 2 Bolt 2 2 2 2 2 1 1 Oil filter cartridge 2 Oil filter wrench 2...

Page 135: ...evel and the vehicle for oil leakage Install the en gine oil tank cover and panel C TIP Refer to steps 10 18 of the To change the engine oil section for the oil filling procedure 10 While sliding the front portion of the cen ter bottom panel on top of the front bot tom panel fit the slots in the center 1 O ring Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf 1 1 Torque wrench 1 U2...

Page 136: ...t the center bottom panel on top of the left and right side panels 11 Install the center bottom panel bolts and then tighten them to the specified torque 1 Center bottom panel 2 Projection 3 Slot 2 1 3 3 1 Center bottom panel 1 U2HC70E0 book Page 23 Monday August 17 2015 11 59 AM ...

Page 137: ...ghtening them to the specified torque 1 Bolt A 2 Bolt B 3 Bolt C 1 2 3 1 Bolt A 2 Bolt B 3 Bolt C Tightening torques Bolt A 7 Nm 0 7 m kgf 5 1 ft lbf Bolt B 7 Nm 0 7 m kgf 5 1 ft lbf Bolt C 7 Nm 0 7 m kgf 5 1 ft lbf 1 3 2 3 U2HC70E0 book Page 24 Monday August 17 2015 11 59 AM ...

Page 138: ...eration Change the transmission oil at the intervals specified in the general maintenance and lu brication chart 1 Rear bottom panel 2 Bolt A 3 Bolt B Tightening torques Bolt A 7 Nm 0 7 m kgf 5 1 ft lbf Bolt B 7 Nm 0 7 m kgf 5 1 ft lbf 3 1 2 2 1 Bolt B Tightening torque Bolt B 7 Nm 0 7 m kgf 5 1 ft lbf 1 1 U2HC70E0 book Page 25 Monday August 17 2015 11 59 AM ...

Page 139: ...ith a clean rag in sert it back into the transmission case without screwing it in and then remove it again to check the oil level TIP The transmission oil level should be between the tip of the dipstick and the maximum level mark 4 If the oil level is at or below the tip of the dipstick add sufficient oil of the recom mended type to raise it to the correct lev el 5 Install the transmission oil fil...

Page 140: ...and new gasket and then tighten the bolt to the specified torque 6 Refill with the specified amount of the recommended oil and then install the transmission oil filler cap TIP Be sure to wipe up any spilled oil 7 Start the engine and drive the vehicle for a few minutes to circulate the transmis sion oil 1 Transmission oil drain bolt 2 Gasket 2 1 Tightening torque Transmission oil drain bolt 20 Nm ...

Page 141: ...ve the final gear oil filler bolt and its gasket and then check the oil level in the final gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level NOTICE Be sure no foreign material enters the final gear case ECB00422 4 Check the gasket for damage and re place it i...

Page 142: ...the brim of the filler hole NOTICE Be sure no foreign material enters the final gear case ECB00422 6 Check the oil filler bolt gasket for dam age and replace it if necessary 7 Install the oil filler bolt and its gasket and then tighten the bolt to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil drain bolt 2 Gasket 2 1 Tightening torque F...

Page 143: ...dd sufficient oil of the recommended type to raise it to the specified level NOTICE Be sure no for eign material enters the differential gear case ECB00412 4 Check the gasket for damage and re place it if necessary 5 Install the differential gear oil filler bolt and its gasket and then tighten the bolt to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1...

Page 144: ...he recommended oil NOTICE Be sure no foreign material enters the differential gear case ECB00412 6 Check the oil filler bolt gasket for dam age and replace it if necessary 7 Install the differential gear oil filler bolt and its gasket and then tighten the bolt to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Differential gear oil drain bolt 2 ...

Page 145: ...uld be between the minimum and maxi mum level marks 4 If the coolant level is at or below the min imum level mark remove the coolant res ervoir cap and add coolant to the maximum level mark NOTICE If cool ant is not available use distilled water or soft tap water instead Do not use hard water or salt water since they are harmful to the engine If water has been used instead of coolant replace it wi...

Page 146: ...od when finished servicing the vehicle TIP The radiator fan automatically switches on or off according to the temperature of the coolant in the radiator If the engine overheats see page 8 66 for instructions EBU32400 Axle boots Check the axle boots for holes or tears If any damage is found have them replaced by a Yamaha dealer Coolant reservoir capacity up to the maximum level mark 0 31 L 0 33 US ...

Page 147: ...ould be a me dium to light tan color the ideal color when the vehicle is ridden normally and all spark plugs installed in the engine should have a similar color If any spark plug shows a dis tinctly different color the engine could be op erating improperly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode ero s...

Page 148: ... possible NOTICE ECB02900 Do not use any tools to remove or install the spark plug cap otherwise the ignition coil coupler may be damaged The spark plug cap may be difficult to remove be cause the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in 1 Spark plug gap ...

Page 149: ... Whenever air filter maintenance is performed check the air inlet for obstructions and the air filter case for dirt and foreign matter check the air filter case check hoses for dirt or water and clean as necessary check the air filter case joints and the rub ber joints to and from the throttle body for proper fit and sealing tighten all fittings securely to avoid the pos sibility of unfiltered air...

Page 150: ...l C page 8 10 2 Remove the air filter case cover by turn ing the air filter case cover lock counter clockwise TIP Make sure that the match mark on the cover lock is aligned with the open match mark on the air filter case cover 3 Remove the foam air filter 1 Air filter case cover 2 Air filter case cover lock 3 Match mark 2 1 3 U2HC70E0 book Page 37 Monday August 17 2015 11 59 AM ...

Page 151: ...oline or other flammable solvents to clean the air fil ter element can cause a fire or explo sion which could lead to serious injury EWB03360 6 Squeeze out the excess solvent NOTICE Do not twist the foam materi al when squeezing it ECB02970 1 Foam air filter 1 1 Foam air filter element 2 Air filter frame 1 2 U2HC70E0 book Page 38 Monday August 17 2015 11 59 AM ...

Page 152: ...tear and replace if damaged or heavily worn 10 Thoroughly apply Yamalube foam air fil ter oil or other quality liquid foam air fil ter do not use a spray type product to the foam material The foam air filter ele ment should be wet but not dripping 11 Pull the foam air filter element over its frame 12 Install the air filter 13 Install the air filter case cover and lock it into place by turning the ...

Page 153: ...EBU35130 Cleaning the air filter case check hoses There is a check hose on each side of the air filter case If dust or water collects in a check hose empty the hose and clean the air filter element and air filter case 1 Match mark 1 1 Air filter case check hose 1 Air filter case check hose 1 1 U2HC70E0 book Page 40 Monday August 17 2015 11 59 AM ...

Page 154: ...leaning the ex haust system 1 Remove the tailpipe cover by removing the bolts 2 Remove the tailpipe bolts 3 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 4 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe cover 2 Bolt 1 2 2 1 Tailpipe bolt...

Page 155: ...n improper fuel air supply or engine noise To prevent this the valve clear ance must be adjusted regularly This adjust ment however should be left to a professional Yamaha service technician EBU32470 Brakes Replacement of brake components requires professional knowledge Brake service should be performed by a Yamaha dealer 1 Gasket 2 Spark arrester 3 Tailpipe Tightening torque Tailpipe bolt 10 Nm 1...

Page 156: ...e place the brake pads as a set The wheels need to be removed to check the brake pads See pages 8 53 8 55 for wheel removal and installation procedures EBU32490 Checking the parking brake pads Each brake pad is provided with a wear indi cator groove which allows you to check the brake pad wear without having to disassem ble the brake If a brake pad has worn to the point that the wear indicator gro...

Page 157: ...ssary TIP The brake and clutch fluid reservoirs are lo cated under the hood page 8 10 For an accurate reading make sure the ve hicle is parked on a level surface 1 Parking brake pad wear indicator groove 1 1 Brake fluid reservoir 2 Clutch fluid reservoir 3 Minimum level mark Specified fluid for brake and clutch systems DOT 4 brake fluid 3 3 1 2 U2HC70E0 book Page 44 Monday August 17 2015 11 59 AM ...

Page 158: ...r the brake or clutch fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECB01161 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indicate worn brake pads or br...

Page 159: ...eleased When depressed it should offer resistance before reaching the floorboard If the pedal offers little resistance when depressed or if the transmission grinds gears when shifting have a Yamaha dealer check the vehicle TIP Don t forget to have your Yamaha dealer check the clutch and transmission as a whole at the intervals specified in the general main tenance and lubrication chart EBU32530 Ch...

Page 160: ...ry EBU35820 Checking the accelerator pedal The accelerator pedal should operate smoothly and spring back to position when released If the pedal free play is out of spec ification have a Yamaha dealer adjust or re place the throttle wire 1 Brake pedal 2 No brake pedal free play 1 2 Accelerator pedal free play 10 0 25 0 mm 0 39 0 98 in 1 Accelerator pedal 2 Accelerator pedal free play 2 1 U2HC70E0 b...

Page 161: ...the free play as follows 3 Remove panel B See page 8 10 4 Release the parking brake lever 5 Slide the rubber cover back on the park ing brake cable 6 Loosen the locknut 7 Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play 8 Tighten the locknut and then slide the rubber cover to its original position 9 Install the panel 1 Parking brake lever ...

Page 162: ...nd lubrication WARNING EWB03380 Damaged cables could restrict operation which may cause an accident or injury In spect control cables frequently and re place damaged cables Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Lubricate the cable ends If the cables do not operate smoothly ask a Yamaha dealer to re place them EBU35200...

Page 163: ...hecked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bushes if necessary Front Rear Recommended lubricant Lithium soap based grease U2HC70E0 book Page 50 Monday August 17 2015 11 59 AM ...

Page 164: ...er and lower arm pivots with a grease gun Front Rear EBU32590 Rear knuckle upper and lower pivot lu brication left and right Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease U2HC70E0 book Page 51 Monday August 17 2015 11 59 AM ...

Page 165: ...rsal joint with a grease gun EBU32600 Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease U2HC70E0 book Page 52 Monday August 17 2015 11 59 AM ...

Page 166: ... frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU35831 Checking and tightening the bead lock Check the bead lock at the intervals specified in the general maintenance and lubrication chart and whenever the tires have been re placed 1 Wheel nut 1 1 U2HC70E0 book Page 53 Monday August 17 2015 11 59 AM ...

Page 167: ...e all four tires at the same time If that is not possible you must replace the tires in pairs front or rear with tires of the same size and type as the originals Never replace just one tire WARNING EWB03390 Installing improper tires on your Yamaha YXZ1000R can affect handling and stabili ty This can cause a loss of control The tires listed below have been approved by Yamaha Motor Manufacturing Cor...

Page 168: ...with a VRLA Valve Regulated Lead Acid battery There is no need to check the electrolyte or to add dis tilled water However the battery lead con nections need to be checked and if necessary tightened WARNING EWB03410 Avoid battery contact with skin eyes or clothing Shield eyes when working near batteries Keep out of reach of children You could be poisoned or severely burned Front tire Size 27 x 9 0...

Page 169: ... Ventilate when charging or using in a closed space Keep batteries away from sparks flames cigarettes or other sourc es of ignition To remove the battery 1 Turn the key to off 2 Remove panel A See page 8 10 3 Remove the battery holding plate by re moving the bolts 4 Disconnect the negative battery lead first then the positive battery lead by remov ing their bolt NOTICE When removing the battery th...

Page 170: ... charger is required Using a con ventional battery charger will damage the battery To store the battery If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00941 Always keep the battery charged ...

Page 171: ...ting Jump starting the vehicle should be avoided The battery should be removed and charged instead WARNING EWB03430 To avoid battery explosion and or serious damage to the electrical system Do not connect the negative lead of the jumper cable to the negative terminal of the battery Do not touch the positive lead of the jumper cable to the negative lead Do not reverse the polarity of the jumper cab...

Page 172: ...rged battery and the other end of the negative lead to an unpainted metal sur face of the passenger seat frame near the center console in the YXZ1000R 6 Start the engine Refer to Starting the engine on page 6 2 7 After the engine starts disconnect the negative lead of the jumper cable from the seat frame and charged battery and then disconnect the positive lead of the jumper cable from the charged...

Page 173: ...electrical circuit in question 1 Main fuse 2 EPS fuse 3 Fuse box 4 Fuel injection system fuse 5 Fuel injection system spare fuse 1 2 3 4 5 1 Headlight fuse HEAD 2 Signaling system fuse SIGNAL 3 Four wheel drive motor fuse DIFF 4 Backup fuse BACK UP for clock 5 Ignition fuse IGNITION 6 Radiator fan motor fuse FAN 7 Spare fuse 8 Auxiliary DC jack fuse TERMINAL 1 2 3 4 5 6 7 8 U2HC70E0 book Page 60 M...

Page 174: ...perage Never use any material in place of the proper fuse Using an improper fuse can cause damage to the electrical system and may lead to a fire EWB03440 Specified fuses Main fuse 40 0 A Fuel injection system fuse 15 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Four wheel drive motor fuse 10 0 A Radiator fan motor fuse 30 0 A Backup fus...

Page 175: ...he headlight fuse and then have a Yamaha dealer check the ve hicle TIP When the headlights are set to low beam only the top half of each lamp will illuminate When the headlights are set to high beam both halves of each lamp will illuminate EBU32681 Headlight beam adjustment NOTICE ECB00691 It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the headlight beam adjust...

Page 176: ... a quick easy procedure for making checks If your vehicle requires any repair take it to a Yamaha deal er The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your vehicle Use only genuine Yamaha parts on your vehicle Imita tion parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can le...

Page 177: ...8 64 8 Gasoline or gasoline vapors can ignite or explode causing severe injury or property damage U2HC70E0 book Page 64 Monday August 17 2015 11 59 AM ...

Page 178: ...maha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Dry Wet Operate the e...

Page 179: ...he recommended coolant tap water can be used temporarily provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See TIP Restart ...

Page 180: ...es several times at slow speeds to let friction dry the brakes Wet brakes may have reduced stopping ability in creasing the chance of an accident EWB03471 NOTICE Excessive water pres sure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electri cal devices Many expensive repair bills have resulted from improper high pressure detergent applications such as t...

Page 181: ... or equivalent product Follow the instruc tions on the product label Operate the vehicle for at least 5 minutes to distribute treated fuel through the fuel system 2 Remove the spark plugs and pour one ta blespoon of fresh engine oil into each cyl inder and then re install the spark plugs Remove the spark plug wires and ground them Operate the electric starter to turn the engine over several times ...

Page 182: ...he battery in an ex cessively warm or cold place more than 30 C 90 F or less than 0 C 32 F Use of Fuel Med Rx or another high quality fuel stabilizer eliminates the need to drain the fuel system Consult a Yamaha dealer if the fuel system needs to be drained U2HC70E0 book Page 3 Monday August 17 2015 11 59 AM ...

Page 183: ...ement 998 cm Bore stroke 80 0 66 2 mm 3 15 2 61 in Compression ratio 11 3 1 Starting system Electric starter Lubrication system Dry sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter cartridge replacement 2 50 L 2 64 US qt 2 20 Imp qt 0 10 ...

Page 184: ...mp qt Air filter Air filter element Wet element Secondary air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 34 0 L 8 98 US gal 7 48 Imp gal Fuel injection Throttle body ID mark 2HC1 00 Spark plug s Manufacturer model NGK CR9EB Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch Clutch type Wet multiple disc Transmission Primary reductio...

Page 185: ...r cargo and accessories Tire air pressure measured on cold tires Recommended Vehicle load 0 195 kg 0 430 lb Front 114 0 kPa 1 140 kgf cm 16 5 psi Rear 128 0 kPa 1 280 kgf cm 18 5 psi Vehicle load 195 kg maximum 430 lb maximum Front 114 0 kPa 1 140 kgf cm 16 5 psi Rear 169 0 kPa 1 690 kgf cm 24 5 psi Minimum Vehicle load 0 195 kg 0 430 lb Front 110 0 kPa 1 100 kgf cm 16 0 psi Rear 124 0 kPa 1 240 k...

Page 186: ...pe Coil spring gas oil damper Wheel travel 410 mm 16 2 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring gas oil damper Wheel travel 432 mm 17 0 in Electrical system Ignition system TCI Charging system AC magneto Battery Model U1 H11L Voltage capacity 12 V 28 0 Ah Bulb voltage wattage quantity Headlight LED Tail brake light LED Neutral indicator light LED Reverse indic...

Page 187: ...5 W 2 Shift timing indicator light LED Fuses Main fuse 40 0 A Fuel injection system fuse 15 0 A EPS fuse 40 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Auxiliary DC jack fuse 10 0 A Backup fuse 10 0 A Four wheel drive motor fuse 10 0 A Radiator fan motor fuse 30 0 A U2HC70E0 book Page 5 Monday August 17 2015 11 59 AM ...

Page 188: ...PRINTED IN USA 2015 08 0 3 1 CR E U2HC70E0 book Page 1 Monday August 17 2015 11 59 AM ...

Page 189: ...erence in case the vehicle is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU32790 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 EBU32800 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ident...

Page 190: ...l be needed to order spare parts from your Yamaha dealer EBU32820 Vehicle Emission Control Information label The Vehicle Emission Control Information la bel is affixed at the location in the illustration This label shows specifications related to ex haust emissions as required by federal law state law and Environment Canada 1 Vehicle identification number 1 1 Model label 1 U2HC70E0 book Page 2 Mon...

Page 191: ...11 3 11 1 Vehicle Emission Control Information label 1 U2HC70E0 book Page 3 Monday August 17 2015 11 59 AM ...

Page 192: ...usly manufactured The warranty set forth in Section A may be transferred to any subsequent owner provided that the period of warranty has not expired and that the CUSTOMER has complied with all terms and conditions of this warranty The subsequent owner has the responsibility for ensuring that a change of registration is sent to YAMAHA at the time of such transfer of ownership This transfer MUST be...

Page 193: ...ssed or implied including any warranty of performance merchantability or fitness for a particular purpose on the part of YAMAHA and any other obligation or liability on behalf of YAMAHA and the above warranty constitutes your sole remedy and the full liability of YAMAHA In no event shall YAMAHA be liable for special incidental or consequential damages howsoever caused whether by negligence or othe...

Page 194: ...c maintenance 8 32 Coolant Pre operation check 5 6 Coolant temperature warning light 4 4 Cup holders 4 26 D Differential gear lock indicator light 4 3 Differential gear oil Periodic maintenance 8 30 Differential gear oil Pre operation check 5 7 Doors 4 20 Drive mode selecting 6 7 Driver seat position 4 22 Drive shaft universal joint lubrication 8 52 Drivetrain icon 4 3 E Engine break in 6 1 Engine...

Page 195: ...ecking 8 43 Passenger handhold Pre operation check 5 8 Pedal lubrication 8 49 R Rear knuckle upper and lower pivot lubrication 8 51 Reverse gear lock lever 4 16 Reverse indicator light 4 2 S Safety information 2 1 Seat belt indicator light 4 6 Seat belts 4 23 Seat belts Pre operation check 5 8 Seats 4 20 Shift lever 4 19 Shift lever operation and reverse driving 6 3 Shift lever Pre operation check...

Page 196: ...k 5 6 Troubleshooting 8 63 Troubleshooting charts 8 65 U Upper and lower arm pivot lubrication 8 51 V Valve clearance 8 42 Vehicle Emission Control Information label 11 2 Vehicle identification number 11 1 W Warranty 11 4 Wheel installation 8 55 Wheel removal 8 53 U2HC70E0 book Page 3 Monday August 17 2015 11 59 AM ...

Page 197: ...U2HC70E0 book Page 4 Monday August 17 2015 11 59 AM ...

Page 198: ... right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manu...

Search results

Summary of Contents for YX10ZPSG

Reviews:

Related manuals for YX10ZPSG

Brands by name

Popular brands

Yamaha YX10ZPSG, Owner'S Manual

Search results

Summary of Contents for YX10ZPSG

Reviews:

Related manuals for YX10ZPSG

Brands by name

Popular brands