Yamaha YXZ1000E Owner'S Manual Download

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8-53

EBU32590

Rear knuckle upper and lower pivot lu-
brication (left and right)

Lubricate the knuckle upper and lower pivots
with a grease gun.

EBU35220

Drive shaft universal joint lubrication

Lubricate the drive shaft universal 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

U2HC7LE0.book Page 53 Wednesday, October 7, 2015 12:09 PM

Summary of Contents for YXZ1000E

Page 1: ...DIC183 2HC F8199 7L YXZ10YPXG OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ... V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title...

Page 3: ...he 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 o...

Page 4: ...fety 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 informa...

Page 5: ...heck 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 EBU33130 YXZ10YPXG OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition September 2015 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 6: ...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 sho...

Page 7: ... 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 lubricat...

Page 8: ...brake lever free play adjustment 8 49 Brake light switch adjustment 8 50 Cable inspection and lubrication 8 50 Pedal lubrication 8 51 Checking the stabilizer bushes 8 51 Upper and lower arm pivot lubrication left and right 8 52 Rear knuckle upper and lower pivot lubrication left and right 8 53 Drive shaft universal joint lubrication 8 53 Steering shaft lubrication 8 53 Wheel removal 8 54 Tire repl...

Page 9: ...Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification number records 11 1 INDEX 12 1 U2HC7LE0 book Page 4 Wednesday October 7 2015 12 09 PM ...

Page 10: ...abels on your 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 replacement label is available from your Yamaha dealer U2HC7LE0 book Page 1 Wednesday October 7 2015 12 09 PM ...

Page 11: ...1 2 1 For Europe 2 1 3 4 5 4 5 6 13 2 8 9 2 14 12 7 2 15 11 10 16 U2HC7LE0 book Page 2 Wednesday October 7 2015 12 09 PM ...

Page 12: ...1 3 1 18 19 17 23 22 20 21 U2HC7LE0 book Page 3 Wednesday October 7 2015 12 09 PM ...

Page 13: ...side 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 1HP F2259 21 1 2 3 U2HC7LE0 book Page 4 Wednesday October 7 2015 12 09 PM ...

Page 14: ...rms completely Inside the vehicle by holding the steering wheel or handhold YAMAHA 1XD K7761 10 AVERTISSEMENT Toute partie du corps bras jambes tête se trouvant hors de l habitacle risque d être é crasée par l arceau de protection Si une roulade ou un capotage semble imminent caler les pieds sur le plancher ou sur les repose pieds et agripper le volant ou la poignée de maintien Ne jamais agripper ...

Page 15: ...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 AVERTISSEMENT La charge ne doit pas exéder 4 5 k...

Page 16: ... 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 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 ...

Page 17: ...he cargo bed or vehicle When loaded with cargo Reduce speed and allow more room to stop Turn gradually and slowly Avoid hills and rough terrain Secure cargo so that it will not shift a loose load could change handling unexpectedly or be thrown forward and strike occupants Keep weight in the cargo bed centered side to side and as low as possible Top heavy loads increase the risk of a rollover Read ...

Page 18: ...e handholds Do not try to stop a vehicle tipover using your arm or leg 5B4 K7762 00 WARNING WARNING AVERTISSEMENT Moving parts can crush and cut Do not operate engine with guard removed 2HC 77762 00 Les pièces mobiles peuvent entrainer des coupures et des blessures par écrasement Ne pas faire fonctionner le moteur si le carter de protection est déposé 14 16 15 U2HC7LE0 book Page 9 Wednesday Octobe...

Page 19: ...ng 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 a ...

Page 20: ... ou le volant Pieds Sur le plancher ou les repose pieds prêts à encaisser le choc portière fermée Head to Toe Safety Checklist YAMAHA 1XD F1558 00 Head Helmet and eye protection Body Seatbelt and protective clothing Hands Inside vehicle and holding the handhold or steering wheel Feet On floor or footrests ready to brace and door closed YAMAHA 2HC F178A 00 20 22 21 U2HC7LE0 book Page 11 Wednesday O...

Page 21: ...que homologué une protection pour les yeux et une tenue de protection Le conducteur doit pouvoir rejoindre aisément toutes les commandes alors qu il est en position assise son dos contre le dossier du siège Les occupants doivent pouvoir rejoindre la poignée de maintien centrale alors que leurs pieds reposent à plat sur le plancher et qu ils sont assis le dos contre le dossier du siège Demeurer ent...

Page 22: ...1 13 1 For Oceania 1 2 3 4 1 1 7 3 6 1 5 8 U2HC7LE0 book Page 13 Wednesday October 7 2015 12 09 PM ...

Page 23: ...1 14 1 10 9 11 U2HC7LE0 book Page 14 Wednesday October 7 2015 12 09 PM ...

Page 24: ...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 1HP F2259 21 2 1 U2HC7LE0 book Page 15 Wednesday October 7 2015 12 09 PM ...

Page 25: ...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 kPa 124 kPa VEHICLE LOAD of 195 kg 430 lbs 326 kg 719 lbs Recommended FRONT REAR Minimum FRONT REAR 114 kPa 169 kPa 110 kPa 165 kPa 16 5 psi 18 5 psi 16 psi 18 psi 16 5 psi 24 5 psi 16 psi 24 psi Vehicle ...

Page 26: ...n severe injury or death from loss of control overturn or other accidents Maximum Load in Cargo Bed 300 lbs 136 kg Maximum Vehicle Load 719 lbs 326 kg Never carry passengers in cargo bed 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 h...

Page 27: ...g 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 a f...

Page 28: ...e 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 the...

Page 29: ...hould wear seat belts properly 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 gogg...

Page 30: ...fore 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 31: ...hat 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 in a ...

Page 32: ...ehicle 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 t...

Page 33: ...xide 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 enclose...

Page 34: ...an 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 suita...

Page 35: ... 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 U2HC7LE0 book Page 8 Wednesday October 7 2015 12 09 PM ...

Page 36: ... 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 U2HC7LE0 book Page 1 Wednesday October 7 2015 12 09 PM ...

Page 37: ...t 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 U2HC7LE0 book Page 2 Wednesday October 7 2015 12 09 PM ...

Page 38: ...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 U2HC7LE0 book Page 3 Wednesday October 7 2015 12 09 PM ...

Page 39: ...ot 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 U2HC7LE0 book Page 1 Wednesday October 7 2015 12 09...

Page 40: ...s 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 1 ...

Page 41: ...nizing 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 completely...

Page 42: ...oes 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 be...

Page 43: ...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 electr...

Page 44: ...l 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 EBU34953 Multi function meter unit The multi function meter unit is equipped with the following speedometer tachometer 1 Tachometer 2 Transmission gear di...

Page 45: ... 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 U2HC7LE0 book Page 7 Wednesday October 7 2015 12 09 PM ...

Page 46: ...it 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 b...

Page 47: ... 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 meter...

Page 48: ...ELECT button and the mi nute digits will start flashing 5 Push the RESET button to set the minu tes 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 H...

Page 49: ...shes 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 indica...

Page 50: ... 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 warni...

Page 51: ... 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 fl...

Page 52: ...nt 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 min...

Page 53: ...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 switc...

Page 54: ...event 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 th...

Page 55: ... 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 U2HC7LE0 book Page 17 Wednesday October 7 2015 12 09 PM ...

Page 56: ...e 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 U2HC7LE0 book Page 18 Wednesday Octo...

Page 57: ...sed 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 U2HC7LE0 book Page 19 Wednesday October 7 2015 12 09 PM ...

Page 58: ...rd 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 U2HC7LE0 book Page 20 Wednesday October 7 2015 12 09 PM ...

Page 59: ...nt 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 cau se the operator or passenger to fall EWB03510 1 Driver seat cushion 1 Passenger seat cushion 1 1 U2HC7LE0 book Page 21 Wednesday October 7 2015 12 09 PM ...

Page 60: ...ust 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 ste...

Page 61: ...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 U2HC7LE0 book Page 23 ...

Page 62: ...ate 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 U2HC7LE0 book Page 24 Wednesday October 7 2015 12 09 PM ...

Page 63: ...oid injury or death never store fuel or flammable liq uids in this storage compartment EWB03230 NOTICE Do not exceed the specified maximum load limit for this storage com partment ECB02090 1 Storage compartment 1 Storage compartment 1 1 Maximum load limit Storage compartment behind driver seat 4 5 kg 10 lb U2HC7LE0 book Page 25 Wednesday October 7 2015 12 09 PM ...

Page 64: ...p 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 abou...

Page 65: ...5020 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 U2HC7LE0 book Page 27 Wednesday October 7 20...

Page 66: ...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 sam...

Page 67: ...t 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 spec...

Page 68: ...n 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 U2HC7LE0 book Page 30 Wednesday Octob...

Page 69: ...orce 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 directi...

Page 70: ...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 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 1 ...

Page 71: ...lf 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 component...

Page 72: ...ting 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 loc...

Page 73: ...ower 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 Di...

Page 74: ...e 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 Stan...

Page 75: ... 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 76: ...ssembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EBU35052 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 requ...

Page 77: ...t switch to off 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 U2HC7LE0 book Page 39 Wednesda...

Page 78: ... 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 43 8 50 Clutch Check operation free play fluid level and fluid leakage Fill with DOT...

Page 79: ... 5 7 Seat belts Check for proper operation and belt wear 5 7 Passenger handhold Check for stability and proper fastening 5 7 7 8 Steering Check for proper operation 5 7 Shift lever Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 8 Instruments lights and switches Check operation and correct if necessary 5 8 8 62 8 63 Wheels and tires Check tire pressure and ...

Page 80: ...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 81: ...ling 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 an...

Page 82: ...hicle Always place a portable fuel container on the ground before filling it Before removing the container cap touch the container with the fuel dispenser nozzle Keep fuel dispenser nozzle in contact with container inlet when fill ing WARNING Never refill a fuel container in the bed of any vehicle Fire may result from a build up of static electricity The discharge of this build up while refueling ...

Page 83: ...f 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 the level up to maximum level mark If coolant is not avail able add distilled water Change the coolant every two years See page 8 33 NOTICE ECB02120 Hard water or salt water is harmful to the engine You may use soft water if you ca...

Page 84: ... that could affect operation Have a Yamaha dealer repair as necessary for proper operation A crash can damage the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necessary replacements made...

Page 85: ...uments lights and switch es are working properly Correct if necessary EBU31851 Control cables When driving in cold weather always make sure all control cables work smoothly before starting 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 Als...

Page 86: ... 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 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 ps...

Page 87: ...rt in the gauge could cause the first reading to be incorrect Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Maximum vehicle load 326 0 kg 719 lb Total weight of operator passenger acces sories and cargo 1 Tire pressure gauge 1 1 Tire wear limit 1 U2HC7LE0 book Page 10 Wednesday October 7 2015 12 09 PM ...

Page 88: ... 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 substan...

Page 89: ...l 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 sho...

Page 90: ...erator 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 onl...

Page 91: ...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 pedal...

Page 92: ...tion 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 ver...

Page 93: ...ver 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 U2HC7LE0 book Page 6 Wednesday October 7 2015 12 09 PM ...

Page 94: ...d 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 differen...

Page 95: ...ential 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 U2HC7LE0 book Page 8 Wednesday October 7 2015 12 09 PM ...

Page 96: ...e 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 str...

Page 97: ...U35761 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 keeping ...

Page 98: ...r older with a valid motor ve hicle license Check country laws for mini mum age requirements The driver must 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 countries have implemented n...

Page 99: ...passenger handhold Allow only one passenger in the vehicle and only in the designated passenger seat Do not 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...

Page 100: ...ork together and when properly used these features will help protect the occupants in the event of an accident If these features are not used prop erly they can cause injury 1 Seat belt 2 Shoulder bolster 3 Door 3 2 1 1 1 Passenger handhold 2 Shoulder bolster 3 Door 3 2 1 U2HC7LE0 book Page 4 Wednesday October 7 2015 12 09 PM ...

Page 101: ... outside of the vehicle can be crushed by the vehicle cage frame Seat belts Seat belts should be worn by the driver and passenger The driver must be sure that the passenger is belted before driving Be sure the seat belt is not twisted is close fitting across the hips and chest and is latched securely Do not wear the seat belt across the abdo men or stomach Do not put the seat belt behind the back ...

Page 102: ...lt properly do the follow ing 1 Hold the latch plate as you pull the belt across your lap and chest Make sure the belt is not twisted and is not caught on any portion of the vehicle your clothing or any equipment you are carrying 2 If the latch plate is not positioned in the correct location along the seat belt squeeze the latch plate ends together along its long edges in order to more eas ily adj...

Page 103: ...r your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the way and then let it retract 6 Check if the seat belt shoulder position suits the size of the driver and passenger To lower the belt insert the belt into the seat belt height adjuster slot as shown To raise the belt remove the belt from the height adjuster slot 1 Buckle 2 L...

Page 104: ...m or hand on the door during operation Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover Passenger handhold The passenger handhold is provided to grip during operation to maintain proper position and balance Holding onto the handhold helps to reduce the likelihood that the pas senger puts a hand outside the vehicle if the vehicle begins to...

Page 105: ...passenger s preference Adjust the handhold position as follows 1 Remove the locking pins 2 Slide the handhold to the desired position and align the holes in the handhold bar with the holes in the handhold supports 1 Passenger handhold 2 Locking pin 1 2 U2HC7LE0 book Page 9 Wednesday October 7 2015 12 09 PM ...

Page 106: ...ats and shoulder bolsters are designed to help keep you in the vehicle Do not put your hand or arm on or outside of the shoul der bolster during operation Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover 1 Handhold support 2 Handhold bar 2 1 1 1 Wire loop 1 U2HC7LE0 book Page 10 Wednesday October 7 2015 12 09 PM ...

Page 107: ... thumbs inside the rim Keep your palms on the outside of the steering wheel Similar to other off road vehicles if the YXZ1000R hits a deep rut or large obstacle the steering wheel could briefly jerk in one di rection or back and forth as the tires and ve 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...

Page 108: ...lowing to reduce risk of injury in an accident Approved motorcycle helmet that fits prop erly CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE 1 Approved motorcycle helmet 2 Eye protection 3 Long sleeved shirt or jacket 4 Gloves 5 Long pants 6 Over the ankle boots 1 2 3 4 5 6 U2HC7LE0 book Page 12 Wednesday October 7 2015 12 09 PM ...

Page 109: ...oggles may reduce the risk of for eign material getting in your eyes and help prevent loss of vision Practice for new Yamaha YXZ1000R users Become familiar with the performance char acteristics of the vehicle in a large flat area that is free of obstacles and other vehicles Practice controlling the accelerator pedal clutch brakes steering and shift lever Drive at slow speeds with gradual accelerat...

Page 110: ...ning Use care in turns turning the steering wheel too far or too fast can result in loss of control or a rollover Slow down before entering turns When making tight turns from a stand still or at slow speeds avoid sudden or hard acceleration Driving aggressively or making abrupt maneuvers even on flat open areas can cause side rollovers Avoid sideways slid ing skidding or back wheel sliding and nev...

Page 111: ...verse until you are thoroughly familiar with each operation Braking When slowing down or stopping take your foot off the accelerator pedal and press the brake pedal smoothly Abrupt or improper use of the brakes can cause the tires to lose traction reducing control of the vehicle and increasing the possibility of an accident Braking ability is affected by type of terrain In most cases gradual appli...

Page 112: ...pply the parking brake Parking on a slope The parking brake is located on the rear drive shaft When the drivetrain is in 2WD mode only the rear wheels will be locked Therefore switch the drive mode to DIFF LOCK before stopping the engine to lock all four wheels when parking In addition to the parking brake leave the transmission in gear to help prevent the vehicle from rolling If you park on a hil...

Page 113: ...icle loading can affect handling as well as the recommended tire pressure See Load ing on page 6 9 and Tire pressure on page 5 8 EBU35572 Operation on different surfaces and terrains Go slowly and proceed with caution when op erating on an unfamiliar surface or terrain This vehicle may handle differently in certain types of terrains or on certain surfaces You may come upon hidden rocks bumps or ho...

Page 114: ... proper driving techniques to avoid rearward for ward or sideways rollovers on hills and slopes Drive straight up and down inclines not across them If crossing a hill is unavoidable drive slowly Turn downhill immediately if you feel the vehicle may tip If you think or feel the vehicle may tip or roll Brace yourself by pressing your feet firmly on the floorboard and keep a firm grip on the steering...

Page 115: ...ound With your foot on the brake pedal look behind you and plan your descent Press the clutch pedal and shift the transmission into reverse so you can use engine braking to slow your descent Re lease the brake and clutch and then begin to coast down the hill Use engine braking as much as possible gently applying the brakes when necessary Downhill Check the terrain carefully before going downhill W...

Page 116: ...ehicle airborne as injury loss of control and damage to the vehicle could occur Pavement This vehicle is designed for off road use only Avoid paved surfaces Turn gradually and go slowly if you must drive on pavement Water If you must cross shallow slow moving water up to the depth of the vehicle s floorboard choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that ...

Page 117: ...he vehicle begin to slide sideways or the back wheels slide during a turn steer into the direction of the slide if possible to re gain directional control For example if you feel the back of the vehicle start to slide to your right steer to the right Brush or wooded areas When operating in areas with brush or trees watch carefully on both sides and above the vehicle for obstacles such as branches ...

Page 118: ...he area thoroughly Look from both your approach side and exit side If you believe you can continue safely choose the path that will allow you to get over the ob stacle and at as close to a right angle as pos sible to minimize vehicle tipping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to chang es in conditions If there is any question about your ab...

Page 119: ...le 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 or ...

Page 120: ...e 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 U2HC7LE0...

Page 121: ...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 U2HC7LE0 book Page 3 Wednesday October 7 2015 12 09 PM ...

Page 122: ...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 necessa...

Page 123: ...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 U2HC7LE0 book Page 5 Wednesday October 7 2015 12 09 PM ...

Page 124: ...mary 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 gea...

Page 125: ...e 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 25...

Page 126: ...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 127: ...aler 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 ITEM...

Page 128: ...he original position and then install the bolts EBU35093 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 panel needs to be removed and installed 1 Hood 2 Bolt 1 2 2 U2HC7LE0 book Page 10 Wednesday October 7 2015 12 09 PM ...

Page 129: ...ove 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 U2HC7LE0 book Page 11 Wednesday October 7 2015 12 09 PM ...

Page 130: ...l 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 U2HC7LE0 book Page 12 Wednesday October 7 2015 12 09 PM ...

Page 131: ... 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 U2HC7LE0 book Page 13 Wednesday October 7 2015 12 09 PM ...

Page 132: ...on 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 U2HC7LE0 book Page 14 Wednesday October 7...

Page 133: ...o 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 134: ... 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 o...

Page 135: ... 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 U2HC7LE0 book Page 17 Wednesday October 7 2015 12 09 PM ...

Page 136: ...d 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 137: ...hile 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 mi nutes and then check the oil level and correct 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 Loosen the left and rig...

Page 138: ...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 U2HC7LE0 book Page 20 Wednesday October 7 2015 12 09 PM ...

Page 139: ... 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 140: ...d amount of the recommended engine oil Check the engine oil level 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 1 O ring Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf 1 1 Torque wrench 1 U2HC7LE0 book Page 22 Wednesday October 7 2015 12 09 PM ...

Page 141: ...s shown and then hook the left and right sides of the center bottom panel into place 11 Install the center bottom panel bolts and then tighten them to the specified torque 1 Center bottom panel 1 1 Center bottom panel 1 U2HC7LE0 book Page 23 Wednesday October 7 2015 12 09 PM ...

Page 142: ...htening 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 U2HC7LE0 book Page 24 Wednesday October 7 2015 12 09 PM ...

Page 143: ...e transmis sion oil at the intervals specified in the general maintenance and lubrication 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 U2HC7LE0 book Page 25 Wednesday October 7 2015 12 09 PM ...

Page 144: ...h 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 fille...

Page 145: ... 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 NOTICE ECB03150 Do not use oils with a diesel specifica tion of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 Transmission oil drain bolt 2 Gasket 2 1 Tightening torq...

Page 146: ...operly 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 EBU36050 Final gear oil Check the oil level and change the final gear oil at the intervals specified in the general maintenance and lubrication chart Checking the final gear oil level 1 Park the vehicle on a level surface 2 Remove the final gear oi...

Page 147: ...n the bolt to the specified torque Changing the final gear oil 1 Park the vehicle on a level surface 2 Place an oil pan under the final gear case to collect the used oil 3 Remove the final gear oil filler bolt the fi nal gear oil drain bolt and their gasket to drain the oil 1 Final gear oil 2 Gasket 3 Final gear oil filler bolt 4 Correct oil level 2 4 3 1 Tightening torque Final gear oil filler bo...

Page 148: ... the oil filler bolt and its gasket and then tighten the bolt to the specified torque 8 Check for oil leakage If oil leakage is found check for the cause EBU36060 Differential gear oil Check the oil level and change the differential gear oil at the intervals specified in the gener al maintenance and lubrication chart Checking the differential gear oil level 1 Park the vehicle on a level surface Ti...

Page 149: ...e differential gear oil filler bolt and its gasket and then tighten the bolt to the specified torque Changing the differential gear oil 1 Park the vehicle on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt the differential gear oil drain bolt and their gasket to drain the oil 1 Differential gear oil filler b...

Page 150: ...d 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 8 Check for oil leakage If oil leakage is found check for the cause 1 Differential gear oil drain bolt 2 Gasket Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf 1 2 Recommended oi...

Page 151: ... should be between the minimum and maxi mum level marks 4 If the coolant level is at or below the mini mum 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 i...

Page 152: ... 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 qt...

Page 153: ...uld 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 si...

Page 154: ...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 S...

Page 155: ...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 156: ... 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 U2HC7LE0 book Page 38 Wednesday October 7 2015 12 09 PM ...

Page 157: ...line 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 U2HC7LE0 book Page 39 Wednesday October 7 2015 12 09 PM ...

Page 158: ...ar 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 ai...

Page 159: ...BU35130 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 U2HC7LE0 book Page 41 Wednesday October 7 2015 12 09 PM ...

Page 160: ...aning 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 1...

Page 161: ... 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 162: ...place the brake pads as a set The wheels need to be removed to check the brake pads See pages 8 54 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 groov...

Page 163: ...ary 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 U2HC7LE0 book Page 45 Wednesday October 7 2015 12 09 PM...

Page 164: ... 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 bra...

Page 165: ...eased 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 Chec...

Page 166: ... 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 U2HC7LE0 boo...

Page 167: ...e 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 fr...

Page 168: ...turn the adjusting nut in direction b EBU35930 Cable inspection and 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 n...

Page 169: ...oth operation EBU32582 Checking the stabilizer bushes The stabilizer bushes must be checked 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 Recommended lubricant Lithium soap based grease U2HC7LE0 book Page 51 Wednesday October 7 2015 12 09 PM ...

Page 170: ...per and lower arm pivot lubrication left and right Lubricate the upper and lower arm pivots with a grease gun Front Rear Recommended lubricant Lithium soap based grease U2HC7LE0 book Page 52 Wednesday October 7 2015 12 09 PM ...

Page 171: ... shaft universal joint lubrication Lubricate the drive shaft universal 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 U2HC7LE0 book Page 53 Wednesday October 7 2015 12 09 PM ...

Page 172: ...e same size and type of tires recommended in this owner s manual The tires that came with your Yamaha YXZ1000R were designed to match the performance ca pabilities and to provide the best combination of handling braking and comfort It is best to replace all four tires at the same time If that is not possible you must replace the tires in 1 Wheel nut 1 1 U2HC7LE0 book Page 54 Wednesday October 7 20...

Page 173: ...le so that the wheel is on the ground 3 Tighten the wheel nuts in a crisscross pattern to the specified torque WARNING EWB03400 Do not reverse the rims on your Yamaha YXZ1000R to widen the track width In stalling wheels improperly increases the risk of wheel failure and accidents EBU35230 Battery The battery is located under panel A See page 8 10 Front tire Size 27 x 9 00R 14NHS Manufacturer model...

Page 174: ...ase of accidental contact with battery electrolyte EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention WARNING EWB03420 Batteries may produce explosive gases Ventilate when charging or using in a closed space Keep batteri...

Page 175: ...5 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have dis charged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories 1 Battery holding plate 2 Bolt 1 2 2 1 Positive battery lead red 2 Negative battery lead black 3 Battery 1 2 3 U2HC7LE...

Page 176: ... month and fully charge it if necessary NOTICE ECB00941 Always keep the battery charged Storing a discharged battery can cause perma nent battery damage To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then the negative battery lead by install ing their bolt NOTICE When installing the battery the main s...

Page 177: ...everse the polarity of the jumper cables when connecting to the batteries However if the vehicle must be jump started proceed as follows 1 Turn the key to off 2 Remove panel A See page 8 10 3 Remove the passenger seat cushion See page 4 20 4 Using a charged 12 volt battery connect the positive lead of the jumper cable to the positive terminal of the battery in the YXZ1000R and the other end of the...

Page 178: ...ry and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the YXZ1000R 8 Install the seat cushion and the panel EBU35250 Fuse replacement The main fuse the fuel injection system fuse the EPS fuse and the fuse box are located under panel A See page 8 10 1 Jumper cable negative lead 1 1 Main fuse 2 EPS fuse 3 Fuse box 4 Fuel injection system fuse 5 Fuel...

Page 179: ...f the specified amperage WARNING Always use a fuse of the specified amperage 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 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 ...

Page 180: ...tion check the 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 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 Signalin...

Page 181: ...e light This model is equipped with an LED tail brake light there are no replaceable bulbs If the tail brake light does not come on check the fuses and then have a Yamaha dealer check the vehicle EBU32700 Troubleshooting Although Yamaha vehicles receive an inspec tion before shipment from the factory trouble may occur during operation Any problem in 1 Headlight beam adjusting screw a b 1 1 Headlig...

Page 182: ... 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 lead to ex pensive repair bills WARNING EWB03450 When checking the fuel system do not smoke and make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces Gasolin...

Page 183: ...ha 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 ele...

Page 184: ... 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 th...

Page 185: ...s 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 th...

Page 186: ...another high quality fuel stabilizer prod uct Follow the instructions on the prod uct 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 eng...

Page 187: ...ove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F Use of fuel stabilizer eliminates the need to drain the fuel system Consult a Yamaha dealer if the fuel system needs to be drained U2HC7LE0 book Page 3 Wednesday October 7 2015 12 09 PM ...

Page 188: ... dB A at 4125 r min EUR FRA GBR Uncertainty of measurement 3 0 dB A EUR FRA GBR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR FRA GBR Uncertainty of measurement 0 0 m s EUR FRA GBR Vibration on handle EN1032 ISO5008 Will not exceed 2 5 m s EUR FRA GBR Uncertainty of measurement 0 2 m s EUR FRA GBR Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Inline 3 cylinder ...

Page 189: ...0 API GL 4 Hypoid gear oil Quantity 0 47 L 0 50 US qt 0 41 Imp qt Differential gear oil Type SAE 80 API GL 4 Hypoid gear oil Quantity 0 18 L 0 19 US qt 0 16 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 31 L 0 33 US qt 0 28 Imp qt Radiator including all routes 3 75 L 3 96 US qt 3 30 Imp qt Air filter Air filter element Wet element Secondary air filter element Oil coated ...

Page 190: ... 1 speed reverse Operation Right hand operation Reverse gear 37 15 2 467 1st 35 17 2 059 2nd 34 22 1 545 3rd 31 26 1 192 4th 25 26 0 962 5th 25 31 0 806 Chassis Frame type Steel tube frame Caster angle 6 80 Trail 33 7 mm 1 33 in Front tire Type Tubeless Size 27 x 9 00R 14NHS Manufacturer model MAXXIS MU09 Rear tire Type Tubeless Size 27 x 11 00R 14NHS Manufacturer model MAXXIS MU10 Loading Maximum...

Page 191: ...mum 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 Front wheel Wheel type Cast wheel Rim size 14 x 6 5AT Rear wheel Wheel type Cast wheel Rim size 14 x 8 0AT Front brake Type Disc brake Operation Unified brake Specified brake fluid DOT 4 Rear brake Type Disc brake Operation Unified brake Specified brake fluid DOT 4 Front suspension Type Double wishbone Sp...

Page 192: ... trouble warning light LED Parking brake indicator light LED Differential gear lock indicator light LED EPS warning light LED Helmet Seat belt indicator light 14 V 0 85 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 ...

Page 193: ... that influence the actual level of exposure of work force in clude the characteristics of the work room the other sources of noise etc i e the num ber of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissible exposure level can vary from country This information however will en able the user of the machine to make a better ...

Page 194: ...TION NUMBER MODEL LABEL INFORMATION EBU32800 Vehicle identification number The vehicle identification number is stamped into the frame The vehicle identification number is used to identify your vehicle EBU33331 Model label The model label can be found under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yama...

Page 195: ...11 2 11 1 Model label 1 U2HC7LE0 book Page 2 Wednesday October 7 2015 12 09 PM ...

Page 196: ...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 Pre operation check 5 7 Doors 4 20 Drive mode selecting 6 7 Driver seat position 4 22 Drive shaft universal joint lubrication 8 53 Drivetrain icon 4 3 E Engine break in 6 1 Engine oil and oil filter Periodic mainte...

Page 197: ...tion 8 51 R Rear knuckle upper and lower pivot lubrication 8 53 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 7 Seats 4 20 Shift lever 4 19 Shift lever operation and reverse driving 6 3 Shift lever Pre operation check 5 8 Shift timing indicator light 4 3 Shock absorber assemblies adju...

Page 198: ...oubleshooting 8 63 Troubleshooting charts 8 65 U Upper and lower arm pivot lubrication 8 52 V Valve clearance 8 43 Vehicle identification number 11 1 W Wheel installation 8 55 Wheel removal 8 54 U2HC7LE0 book Page 3 Wednesday October 7 2015 12 09 PM ...

Page 199: ...U2HC7LE0 book Page 4 Wednesday October 7 2015 12 09 PM ...

Page 200: ...Original instructions PRINTED IN USA 2015 10 0 3 1 CR E U2HC7LE0 book Page 1 Wednesday October 7 2015 12 09 PM ...

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Yamaha YXZ1000E, Owner'S Manual

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