Yamaha YXZ10YEXR Owner'S Manual Download Page 184

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9-59

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.

EBU41080

Drive shaft spline lubrication

Lubricate the drive shaft splines.

Recommended lubricant:

Lithium-soap-based grease

Recommended lubricant:

Lithium-soap-based grease

UBDW11E0.book Page 59 Wednesday, June 7, 2023 11:11 AM

Summary of Contents for YXZ10YEXR

Page 1: ...DIC183 OWNER S MANUAL BDW F8199 11 LIT 11626 37 28 YXZ10YEXR YXZ10YEZR READ THIS MANUAL CAREFULLY It contains important safety information...

Page 2: ...reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently w...

Page 3: ...tenance and inspection procedures If you have any ques tions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING EWB04330 Read this manual carefully before op...

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 situ...

Page 5: ...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 stat...

Page 6: ...nch switch YXZ10YEZR 5 20 On Command drive knob 2WD 4WD DIFF LOCK 5 21 Accelerator pedal 5 22 Brake pedal 5 22 Parking brake lever 5 23 YCC S and shift modes 5 23 Drive select lever and shift paddles...

Page 7: ...lights and switches 6 8 Control cables 6 8 Tires 6 8 OPERATION 7 1 Engine break in 7 1 Starting the engine 7 2 Operating the transmission 7 3 Dynamic clutch engagement 7 7 Launch system operation 7 8...

Page 8: ...lutch 9 53 Checking the brake pedal 9 54 Checking the accelerator pedal 9 54 Parking brake lever free play adjustment 9 55 Brake light switch 9 56 Cable inspection and lubrication 9 56 Pedal lubricati...

Page 9: ...ICATIONS 11 1 CONSUMER INFORMATION 12 1 Vehicle Emission Control Information label 12 1 Emission Regulation California 12 1 Use of your vehicle data 12 2 NOISE REGULATION for USA 12 4 MAINTENANCE RECO...

Page 10: ...CLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION KEY IDENTIFICATION NUMBER EBU32800 Vehicle identification number The vehicle identification number is stamped into the frame The vehicle identificatio...

Page 11: ...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 1 Model label 1 1 1 1 Mode...

Page 12: ...1 3 1 1 Key identification number 1 UBDW11E0 book Page 3 Wednesday June 7 2023 11 11 AM...

Page 13: ...2 1 2 EBU33070 LOCATION OF THE WARNING AND SPECIFICATION LABELS 9 4 3 5 5 6 7 4 8 3 3 9 3 1 2 10 10 11 11 UBDW11E0 book Page 1 Wednesday June 7 2023 11 11 AM...

Page 14: ...ontain 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...

Page 15: ...ns Do not incinerate puncture or open B4J F2259 00 B4J K8483 00 WARNING Do not rest hands or arms on door or shoulder bolster To avoid Injury keep hands and arms completely Inside the vehicle by holdi...

Page 16: ...5 psi 19 psi VEHICLE LOAD of 441 lbs 200 kg 668 lbs 303 kg Recommended FRONT REAR Minimum FRONT REAR 16 psi 24 psi 15 psi 23 psi 110 kPa 140 kPa 103 kPa 131 kPa 110 kPa 170 kPa 103 kPa 159 kPa Vehicle...

Page 17: ...p 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 i...

Page 18: ...and door YAMAHA MOTOR CORPORATION U S A certifies this ROV complies with the American National Standard for Recreational Off Highway Vehicles ANSI ROHVA 1 2016 Standard B4J F4163 01 8 9 UBDW11E0 book...

Page 19: ...upures et des blessures par crasement Ne pas faire fonctionner le moteur si le carter de protection est d pos BDW F1684 00 INTAKE MANIFOLD 1 PRESS SENSOR VACUUM HOSE ROUTING EMISSION HOSE ROUTING THRO...

Page 20: ...so use these 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...

Page 21: ...ger should 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...

Page 22: ...e 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...

Page 23: ...e Abrupt maneuvers or aggressive driving even on flat open areas can cause loss of control including rollovers The YXZ10YEXR YXZ10YEZR has higher ground clearance and other fea tures to handle rugged...

Page 24: ...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 whe...

Page 25: ...oxide 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 engi...

Page 26: ...maha 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...

Page 27: ...te Refer to page 9 61 for tire specifications and more information on replacing your tires Towing the vehicle This vehicle is not designed to be towed The transmission is properly lubricated only when...

Page 28: ...2 Headlights 3 Brake fluid reservoir 4 YCC S clutch fluid reservoir 5 Rearview mirror YXZ10YEZR 6 Interior light YXZ10YEZR 7 Battery 8 Fuses 9 Driver seat belt 10 Coolant reservoir 11 Exhaust pipe 12...

Page 29: ...1 10 2 3 4 1 1 Cargo bed 2 Engine 3 Passenger seat belt 4 Sun top YXZ10YEZR 5 Door 6 Fuel tank cap 7 Transmission 8 Shoulder bolster 9 Engine oil tank 10 Rear shock absorber 11 Muffler UBDW11E0 book P...

Page 30: ...ction meter unit 2 Steering wheel 3 Main switch 4 Shift mode selector 5 Winch switch YXZ10YEZR 6 Interior light switch YXZ10YEZR 7 Display unit 8 Passenger handhold 9 Glove compartment 10 Parking brak...

Page 31: ...and the multi function meter can be confirmed at this time EBU31241 Off position All electrical circuits are switched off The key can be removed EBU31251 Start position The electric starter is engage...

Page 32: ...dicator light 4 Parking brake indicator light 5 Reverse indicator light 6 Neutral indicator light 7 Engine trouble warning light 8 High beam indicator light 9 Half clutch indicator light 10 Launch sys...

Page 33: ...n icon indicates what type of drive mode is currently selected When 2WD is selected the icon will turn off When 4WD is selected is displayed And when 4WD with differential lock is selected is dis play...

Page 34: ...This warning light comes on when the coolant temperature and therefore the engine is out side its normal operating temperature range The warning light comes on in blue to inform the driver that the v...

Page 35: ...his warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine When this occurs the display will indicate an error code see page 5 18 Have a Yamaha deal...

Page 36: ...n shifting gears The indicator light may also come on during engine braking or in other situations The electrical circuit of the indicator light can be checked by turning the key to on If the indicato...

Page 37: ...ff as normal in 1st 2nd gear or retry activating the launch system EBU40860 YCC S system warning light This warning light comes on when an error has occurred or a malfunction has been de tected in the...

Page 38: ...ing into neutral is impossible using the shift paddles and drive select lever proceed as follows if it is necessary to move the vehi cle after it has stopped 1 Turn the key to off 2 Remove panel B pag...

Page 39: ...reminder light comes on and stays on while the key is turned to on to remind the occupants to always wear a helmet If the reminder light does not come on when the key is turned to on have a Yamaha de...

Page 40: ...rature display fuel gauge transmission gear display shift light control mode error code display 1 Tachometer 2 Transmission gear display 3 Shift light 4 Speedometer 5 SELECT button 6 MODE button 7 RES...

Page 41: ...T button pushed and turn the key to on Tachometer The tachometer shows the engine speed in crankshaft revolutions per minute r min When the vehicle is first powered on the ta chometer needle will swee...

Page 42: ...e distance that can be traveled with a full tank of gas etc Push the SELECT button to switch between the odometer ODO and the tripmeters TRIP A and TRIP B in the following order ODO TRIP A TRIP B ODO...

Page 43: ...ant temperature display in the following order CLOCK HOUR VOLTAGE coolant temperature CLOCK To set the clock 1 Set the display to the clock 2 Push both the SELECT button and RESET button until the hou...

Page 44: ...s LO or HI there may be trouble with the battery charging circuit or the battery may be faulty If this occurs have a Yamaha dealer check or repair the vehicle Coolant temperature display When the cool...

Page 45: ...the key to off then hold the RESET button pushed and turn the key to on The radiator fans turn on and off automati cally according to the coolant temperature Fuel gauge The fuel gauge indicates the am...

Page 46: ...N and by the neutral indicator light Shift light control mode The shift light has three settings which can be adjusted Flashing pattern this function allows you to choose whether or not the light will...

Page 47: ...ft light flashes when acti vated The shift light will confirm this setting by flashing four times per sec ond Off the shift light is deactivated in oth er words it does not come on or flash The shift...

Page 48: ...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 The tachometer needle will start over at 7000 r min after 12000 r min 1 Pu...

Page 49: ...Yamaha deal er 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 EBU35471 Ligh...

Page 50: ...or light switch YXZ10YEZR Push the upper side a of the interior light switch to turn on the interior lights and push the lower side b of the switch to turn off the lights EBU38922 Winch switch YXZ10YE...

Page 51: ...the terrain and driv ing conditions 2WD two wheel drive Power is sup plied to the rear wheels only 4WD four wheel drive Power is sup plied to the front and rear wheels DIFF LOCK four wheel drive with...

Page 52: ...eed and thus vehicle speed Release the accelator pedal and spring tension will re turn the pedal to idle position EBU31421 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Accelerator...

Page 53: ...shift modes This vehicle is equipped with a sequential 6 speed 1 reverse transmission controlled by the Yamaha Chip Controlled Shift system YCC S The drive select lever is used to shift the transmissi...

Page 54: ...ts Opti mized for lower engine speeds and more re laxed riding TIP To use the drive select lever you must be pressing the brake pedal and be stopped be traveling less than 5 km h 3 mph and the engine...

Page 55: ...e to shift down TIP Read Operating the transmission for shift ing instructions See page 7 3 EBU31451 Fuel tank cap Remove the fuel tank cap when refueling To open turn counterclockwise When finished r...

Page 56: ...rely latched Be sure the door is SE CURELY LATCHED AFTER CLOSING IT EBU33461 Seats To remove a seat cushion lift the front of the cushion and then pull the cushion off 1 Door 2 Handle 2 1 1 Driver sea...

Page 57: ...cause the operator or passenger to fall EWB03510 EBU34993 Adjusting the driver seat position The driver seat position can be adjusted to suit the driver s preference WARNING Nev er adjust the seat pos...

Page 58: ...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 steering wheel position pull the ste...

Page 59: ...elts properly while rid ing in the vehicle See page 8 5 TIP If the vehicle is driven without the driver seat belt fastened a buzzer will sound If the vehicle is driven without the driver seat belt fas...

Page 60: ...p 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 EWB03...

Page 61: ...22 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...

Page 62: ...ing force adjusting screw Crossover adjusting nut WARNING EWB04140 Suspension components become hot during operation Never touch the com pression damping force adjusting bolt and screw the rebound dam...

Page 63: ...s are ineffective and may damage the suspension NOTICE ECB00091 Never turn an adjusting mechanism be yond the minimum and maximum settings Spring preload 1 Elevate the vehicle and place a suitable sta...

Page 64: ...knut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00082 6 Install the hood Spring preload setting Minimum soft Dis...

Page 65: ...st the crossover setting a similar distance whenever the spring preload is adjusted The crossover setting is measured from the bottom of the spring retainer to the top of the crossover locknut 1 Loose...

Page 66: ...l tool 2 3 8 inch 9 5 mm drive wrench 3 Crossover locknut 1 2 3 90 1 Distance B 2 Spring retainer 3 Crossover locknut 4 Crossover adjusting nut Crossover setting Minimum soft Distance B 19 2 mm 0 76 i...

Page 67: ...force adjusting screw in direction a to increase the rebound damping force and thereby harden the damp ing and in direction b to decrease the re bound damping force and thereby soften the damping Tigh...

Page 68: ...pression damping turn the adjusting bolt in direction b Rebound damping setting Minimum soft 26 click s in direction b Standard 12 click s in direction b Maximum hard 1 click s in direction b 1 High s...

Page 69: ...Read and understand the following information be fore handling the shock absorber assem blies Do not tamper with or attempt to open the cylinder assemblies Do not subject the shock absorber as semblie...

Page 70: ...ting screw Crossover adjusting nut WARNING EWB04140 Suspension components become hot during operation Never touch the com pression damping force adjusting bolt and screw the rebound damping force adju...

Page 71: ...ehicle and place a suitable stand under the frame 2 Loosen the locknut 3 Turn the spring preload adjusting nut in direction a to increase the spring pre load and thereby harden the suspension and in d...

Page 72: ...ring TIP It is recommended to adjust the crossover setting a similar distance whenever the spring preload is adjusted The crossover setting is measured from the bottom of the spring retainer to the to...

Page 73: ...o increase the crossover setting and in direction b to decrease the cross over setting 1 Distance B 2 Spring retainer 3 Crossover locknut 4 Crossover adjusting nut 3 2 4 1 1 Special tool 2 3 8 inch 9...

Page 74: ...ring retainer 3 Crossover locknut 4 Crossover adjusting nut Crossover setting Minimum soft Distance B 45 3 mm 1 78 in Standard recommended Distance B 58 0 mm 2 28 in Maximum hard Distance B 70 7 mm 2...

Page 75: ...e compression damping 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 there...

Page 76: ...ten 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 fro...

Page 77: ...ve gas pressure Do not deform or damage the cylinders in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take t...

Page 78: ...g can overheat the winch motor and can drain the vehicle s battery even when the engine is idling Al low the winch motor to cool and the bat tery to recharge between uses EBU35057 Auxiliary DC jack Th...

Page 79: ...cuit and cause the fuse to blow If accessories are used while the head lights are on and or without the engine running the battery may discharge Do not use an automotive cigarette light er or other ac...

Page 80: ...ccident or equipment damage Do not operate the vehicle if you find any problem If a problem can not be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer...

Page 81: ...shift paddles Check for proper operation 6 7 YCC S clutch Check operation Check fluid level in reservoir If necessary add specified brake fluid to specified level Check hydraulic system for leakage 6...

Page 82: ...rake fluid leakage Check to see if any brake 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 inspec...

Page 83: ...tely 4 Be sure the fuel tank cap is closed se curely WARNING EWB02532 Gasoline is poisonous and can cause inju ry or death Handle gasoline with care Never siphon gasoline by mouth If you should swallo...

Page 84: ...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 res...

Page 85: ...or pedal is not in correct work ing order have the vehicle inspected before starting off EBU31800 Seat belts Make sure that the seat belts are not frayed torn stretched or damaged The seat belts must...

Page 86: ...and shift paddles The drive select lever and shift paddles should move smoothly and return to their original position EBU36672 YCC S clutch Check the YCC S clutch fluid level and cor rect if necessar...

Page 87: ...t the tire pressure before each ride Check tires for wear and damage Tire pressure Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first...

Page 88: ...kPa 1 400 kgf cm 20 0 psi Front Minimum 103 0 kPa 1 030 kgf cm 15 0 psi Rear Minimum 131 0 kPa 1 310 kgf cm 19 0 psi VEHICLE LOAD of 200 0 303 0 kg 441 668 lb FRONT Recommended 110 0 kPa 1 100 kgf cm...

Page 89: ...e tire tread depth has worn to 3 mm 0 12 in replace the tire If the tire has a nail or glass fragments in it or if the sidewall is cracked replace the tire 1 Tire tread depth 1 UBDW11E0 book Page 10 W...

Page 90: ...s 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 eng...

Page 91: ...N and the neutral indicator light should come on The engine can be started in any gear if the brake pedal is applied However it is recommended to shift into neutral before starting the engine 4 With...

Page 92: ...idle speed You can change between forward D and reverse R directly it is not necessary to select neutral N The transmission must be in 1st or 2nd gear in order to use the drive select lever to shift i...

Page 93: ...B03370 Even with the transmission in the neutral position do not coast for long periods of time with the engine off The transmission is properly lubricated only when the engine is running Inadequate l...

Page 94: ...gear by holding the shift paddle until the transmission gear display shows 2 TIP When high clutch temperature is detected starting out in 2nd gear shifting into 2nd gear while the vehicle is stopped i...

Page 95: ...shown in the fol lowing table TIP When coming to a stop under normal condi tions the transmission will auto downshift to 1st gear To drive in reverse WARNING EWB03300 Before you shift into reverse ma...

Page 96: ...k behind you then release the brake pedal and press the accelerator pedal gradually 6 Continue to watch to the rear while driv ing in reverse EBU37791 Dynamic clutch engagement When driving up a steep...

Page 97: ...ng conditions are present the engine is not warmed up or is overheat ed the driver seat belt is not latched the differential gear is locked DIFF LOCK is selected or the differential gear lock indicato...

Page 98: ...rator pedal during the launch sequence will cancel the launch sys tem The engine speed at launch must be be tween 5000 10000 r min If you release one shift paddle or if a sys tem restriction is detect...

Page 99: ...unch system and the launch system indicator light will turn off NOTICE ECB03430 Do not make consecutive launches with out allowing the clutch to cool down Oth erwise the clutch system may be damaged U...

Page 100: ...elected drive mode The drive mode icon and the indicator 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...

Page 101: ...ng 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 transi...

Page 102: ...ent when carrying a load Cargo bed Use the hooks equipped on the cargo bed page 5 31 to tie down loads Make sure the load is securely fastened down centered in the cargo bed and not top heavy Never al...

Page 103: ...kg 300 lb Do not exceed the maximum loading limit for the vehicle 303 0 kg 668 lb EBU40423 Towing the vehicle NOTICE ECB04011 Do not tow this vehicle for extended dis tances or at speeds of more than...

Page 104: ...VEHICLE This off road vehicle will handle and maneu ver differently from cars ATVs go carts golf cars and grounds keeping vehicles The YXZ10YEXR YXZ10YEZR has higher ground clearance and other feature...

Page 105: ...16 or older with a valid motor ve hicle license Check local laws for minimum age requirements The driver must be able to place both feet flat on the floorboard while seated upright with his her back...

Page 106: ...able to place both feet on the floorboard while seated upright with his her back against the backrest Your passenger must be able to reach and hold the passenger handhold Allow only one passenger in t...

Page 107: ...hanges to the ve hicle The YXZ10YEXR YXZ10YEZR comes with a variety of features to help reduce the risk of driver and passenger injury These features work together and when properly used these feature...

Page 108: ...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...

Page 109: ...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 y...

Page 110: ...est 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 th...

Page 111: ...ed 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 handh...

Page 112: ...n 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 starting off 1 Pa...

Page 113: ...The 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 Kee...

Page 114: ...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 exam...

Page 115: ...ries 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 o...

Page 116: ...id 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...

Page 117: ...in directional control 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 you...

Page 118: ...elerator 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 vehi...

Page 119: ...inue to apply the 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 lef...

Page 120: ...XZ10YEZR has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some vehicles may not Abrupt maneuvers or aggressive driving can cause...

Page 121: ...ce 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 tractio...

Page 122: ...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 t...

Page 123: ...urn 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 the brakes If nec essary apply the bra...

Page 124: ...ed 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 p...

Page 125: ...ion 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 UBDW11E0 book Page 22 Wed...

Page 126: ...ile 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 specifie...

Page 127: ...e you the owner with the necessary information for completing your own preventive maintenance and minor repairs Other tools and equipment are required for certain service items If you do not have a to...

Page 128: ...l system NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 15 80 160 160 320 1 Fuel line Check fuel hose for cracks or da...

Page 129: ...l system for damage Replace if necessary 8 Air induction sys tem Check the air cut off valve reed valve and hose for damage Check condition and clean or replace if nec essary 9 Spark arrester Clean NO...

Page 130: ...very 2 years 2 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...

Page 131: ...rs 11 YCC S clutch hoses Replace Every 4 years 12 Brake system Check operation brake pad wear and for fluid leakage Correct if necessary replace pads if worn to the limit 13 Parking brake Check operat...

Page 132: ...quipped models Every 500 km 300 mi 18 Wheel bearings Check bearing assemblies for loose ness damage Replace if damaged 19 Front and rear suspension Check operation and for oil leakage Correct if neces...

Page 133: ...m 600 mi 26 Drive shaft spline Lubricate with polyurea grease Every 1000 km 600 mi 27 Engine mounts Check for cracks or damage Check bolt tightness 28 Front and rear axle boots Check for cracks or oth...

Page 134: ...as rain mud sand or unusually dusty areas The service items contained herein should not be considered exhaustive therefore have your YXZ10YEXR YXZ10YEZR checked and serviced by your Yamaha dealer at r...

Page 135: ...s section each time a hood needs to be removed and installed Hood A To remove the hood Remove the bolts and then pull the hood off as shown To install the hood Place the hood in the original position...

Page 136: ...the hood 1 Remove the hood A 2 Remove the quick fastener screws and the bolts 3 Remove the quick fastener screws 1 Hood B 2 Bolt 3 Quick fastener screw 1 1 3 3 3 3 2 2 2 2 UBDW11E0 book Page 11 Wednes...

Page 137: ...hood off as shown TIP Lift up the end of the front fender and pull the hood To install the hood Place the hood in the original position and then install the bolts and the quick fastener screws 1 Hood...

Page 138: ...tenance jobs de scribed in this chapter Refer to this section each time a panel needs to be removed and installed Panel A To remove the panel 1 Unhook the projections as shown 1 Panel A 2 Panel B 1 1...

Page 139: ...en remove the pan el YXZ10YEZR To install the panel 1 Connect the interior light couplers YXZ10YEZR 2 Place the panel in the original position 1 Panel A 2 Projection 1 2 2 1 2 2 1 Interior light coupl...

Page 140: ...A 3 Remove the top cover by removing the quick fastener screw and the bolts 4 Remove the passenger seat cushion See page 5 26 5 Remove the passenger seat by removing the bolts 1 Top cover 2 Bolt 3 Qui...

Page 141: ...o 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 1 2 2 1 3 3 2 2 1 Panel B 2 Quick fastener...

Page 142: ...al position 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 Panels C and D To remove a panel 1 Pull the tab...

Page 143: ...9 18 9 2 Remove the panel as shown 1 Panel C 2 Panel D 3 Tab 1 Tab 2 Panel lock 1 1 3 2 3 1 3 2 3 1 2 1 Panel C 1 Panel D 1 1 1 1 1 1 UBDW11E0 book Page 18 Wednesday June 7 2023 11 11 AM...

Page 144: ...t is pointing rear ward EBU40993 Bottom panels The bottom panels shown need to be re moved to perform some of the maintenance jobs described in this chapter Refer to this section each time a bottom pa...

Page 145: ...t as shown 3 Remove the rear bottom panel by remov ing the bolts To install the rear bottom panel 1 Install the rear bottom panel by installing the bolts and then tightening them to the specified torq...

Page 146: ...1 Bolt A 2 Bolt B 1 Rear bottom panel 2 Bolt A 3 Bolt B 1 2 1 1 2 2 3 3 2 2 Tightening torques Bolt A 7 N m 0 7 kgf m 5 2 lb ft Bolt B 7 N m 0 7 kgf m 5 2 lb ft 1 Bolt Tightening torque Side panel bol...

Page 147: ...to remove it To install the center bottom panel 1 Slide the front portion of the center bot tom panel into place as shown and then hook the left and right sides of the center bottom panel into place...

Page 148: ...to the specified torques 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 N m 0 7 kgf m 5 2 lb ft Bolt B 7 N m 0 7 kgf m 5 2 lb ft Bolt C 7 N m 0 7 kgf m 5 2 lb...

Page 149: ...ce 2 Remove panel D See page 9 13 3 Start the engine and warm it up 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...

Page 150: ...f necessary 8 Install the engine oil tank filler cap 9 Install the panel To change the engine oil 1 Park the vehicle on a level surface 2 Remove panel D See page 9 13 3 Remove the engine oil tank cove...

Page 151: ...ngine oil 7 Remove the oil tank drain bolt and used gasket 8 Place an oil pan under the engine to col lect the used engine oil 9 Remove the engine oil drain bolt and used gasket 1 Engine oil tank fill...

Page 152: ...olts to the specified torques 11 Add 2 00 L 2 11 US qt 1 76 Imp qt of the recommended engine oil to the oil tank 12 Check the O ring for damage and re place it if necessary 1 Engine oil drain bolt 2 G...

Page 153: ...and tighten the engine oil tank filler cap 17 Start the engine and let it idle for several minutes During this time check for oil leakage If any oil leaks are found stop the engine and check for the...

Page 154: ...oil leakage may occur TIP An oil filter wrench is available from a Yamaha dealer 5 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 i...

Page 155: ...it will use Yamalube oils take full advantage of the base oil s qualities and blend in the ideal bal ance of additives to make sure the final oil clears our performance standards Thus Yamalube mineral...

Page 156: ...t again TIP The transmission oil level should be between the minimum and the maximum level mark 4 If the oil level is at or below the minimum level mark add oil TIP Add a sufficient amount to raise to...

Page 157: ...ke care not to lose the bolt 4 After draining the oil install the transmis sion oil drain bolt with a new gasket 5 Tighten the drain bolt to the specified torque 6 Fill the transmission with the speci...

Page 158: ...See page 9 19 3 Follow steps 1 3 of the To change the transmission oil section for the oil drain ing procedure 4 Remove the oil filter cartridge with an oil filter wrench Make sure the O ring is re m...

Page 159: ...d torque 7 Follow steps 4 9 of the To change the transmission oil section for the oil filling procedure 8 Install the bottom panel EBU36055 Final gear oil Check the oil level and change the final gear...

Page 160: ...se 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 4 Check the gask...

Page 161: ...oil up to the brim of the filler hole 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...

Page 162: ...ar oil level 1 Park the vehicle on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil lev el It should be up to the brim of the filler hole 3 If the l...

Page 163: ...olt and their gasket to drain the oil 4 Install the differential gear oil drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill the differential gear case with the r...

Page 164: ...ater at a 1 1 ratio NOTICE ECB02190 Mix antifreeze with distilled water only However if distilled water is not available soft water may be used for refilling Do not use hard water or salt water since...

Page 165: ...If water has been used instead of coolant replace it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corro sion If water has been added to the co...

Page 166: ...y a Yamaha dealer EBU35121 Checking the spark plugs The spark plug is an important engine com ponent which should be periodically checked preferably by a Yamaha dealer Since heat and deposits will cau...

Page 167: ...maha dealer check the vehicle If a spark plug shows signs of electrode ero sion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be...

Page 168: ...p 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 EBU38320 Air filter maintenance This model is...

Page 169: ...d the pos sibility of unfiltered air entering the engine NOTICE ECB02270 Never operate the engine with the air filter element removed Doing so would allow unfiltered air to enter causing rapid en gine...

Page 170: ...ir filter 3 Remove the foam air filter element from the air filter frame 1 Air filter case cover lock 2 Air filter case cover 3 Match mark 1 2 1 2 3 1 Foam air filter 1 1 1 UBDW11E0 book Page 45 Wedne...

Page 171: ...t twist the foam materi al when squeezing it ECB02970 6 Wash the foam material in warm soapy water to remove remaining solvent then rinse thoroughly with plain warm water 7 Squeeze out the excess wate...

Page 172: ...ir filter case cover and lock it into place by turning the air filter case cover lock clockwise TIP Make sure that the match mark on the cover lock is aligned with the close match mark on the air filt...

Page 173: ...the exhaust system is cool before cleaning the spark arrester Do not start the engine while cleaning the ex haust system 1 Remove the tailpipe cover by removing the tailpipe cover bolts 1 Air filter c...

Page 174: ...tion of the tailpipe and inside of the tailpipe housing 5 Install the gasket and then insert the tail pipe into the muffler and align the bolt holes 6 Install the tailpipe bolts and tighten them to th...

Page 175: ...ould be performed by a Yamaha dealer WARNING EWB02572 Operating with improperly serviced or ad justed brakes could lead to a loss in brak ing ability and an accident EBU35150 Checking the front and re...

Page 176: ...he wear indicator groove has al most disappeared have a Yamaha dealer re place the brake pads as a set EBU36610 Checking the brake and YCC S clutch fluid levels Before starting off check that the brak...

Page 177: ...S clutch system reducing braking or YCC S clutch performance Clean the filler caps before removing Use only DOT 4 brake fluid from a sealed container Use only the specified brake fluid other wise the...

Page 178: ...he YCC S clutch system for leakage If the brake or YCC S clutch fluid level goes down suddenly have a Yamaha dealer check and repair the vehicle before any further opera tion EBU36550 Brake and YCC S...

Page 179: ...no brake drag If the brakes feel soft or spongy this could in dicate air in the brake system Have a Yamaha dealer check the brake system if necessary EBU35821 Checking the accelerator pedal The accele...

Page 180: ...e play The maximum free play is equal to 3 clicks of the parking brake lever If neces sary adjust the free play as follows 3 Remove panel B See page 9 13 4 Release the parking brake lever 5 Slide the...

Page 181: ...is a component of the YCC S system it must be adjusted by a Yamaha dealer who has the necessary professional knowledge and experience EBU32561 Cable inspection and lubrication WARNING EWB03380 Damage...

Page 182: ...ally to prevent rust and ensure smooth operation EBU32583 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenan...

Page 183: ...pper 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 UBDW11E0 book Page 58 Wednesda...

Page 184: ...gun EBU35220 Drive shaft universal joint lubrication Lubricate the drive shaft universal joint with a grease gun EBU41080 Drive shaft spline lubrication Lubricate the drive shaft splines Recommended...

Page 185: ...emoval 1 Loosen the wheel nuts 2 Elevate the vehicle and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel Recommended lubricant Polyurea grease Recommended lu...

Page 186: ...placed Tighten the bead lock bolts to the specified torque in a crisscross pattern EBU32620 Tire replacement Always use the same size and type of tires recommended in this owner s manual The tires tha...

Page 187: ...ffect han dling and stability This can cause a loss of control The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model EBU33090 Wheel installation...

Page 188: ...harged re charge it as soon as possible 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...

Page 189: ...o off 2 Remove panel A See page 9 13 3 Remove the battery holding plate by re moving the bolts 4 Disconnect the negative battery leads first then the positive battery leads by re moving their bolt NOT...

Page 190: ...ecified on the battery itself Select a suitable charger and follow the manufacturer s instructions or have a Yamaha dealer charge it for you 1 Negative battery leads black 2 Positive battery leads red...

Page 191: ...k it at least once a month and fully charge it if necessary NOTICE ECB00942 Always keep the battery charged Stor ing the battery in a discharged state for an extended period of time will cause permane...

Page 192: ...e sure the battery leads are installed as shown Fully charge the battery before installing it 1 Negative battery leads black 2 Positive battery leads red 3 Battery 1 1 3 1 3 2 2 1 Negative battery lea...

Page 193: ...teries However if the vehicle must be jump started proceed as follows 1 Turn the key to off 2 Remove panel A See page 9 13 3 Remove the passenger seat cushion See page 5 26 4 Using a charged 12 volt b...

Page 194: ...f the jumper cable from the charged battery and the battery in the YXZ10YEXR YXZ10YEZR 8 Install the seat cushion and the panel EBU35256 Fuse replacement The main fuse the fuel injection system fuse t...

Page 195: ...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...

Page 196: ...ection 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 Sub radiator fan motor fuse 30 0 A Ra...

Page 197: ...ll illuminate When the headlights are set to high beam both halves of each lamp will illuminate TIP The auxiliary lights YXZ10YEZR come on only when set to high beam EBU32681 Headlight beam adjustment...

Page 198: ...e or more interior lights do not come on check for a loose connection check the fus es and then have a Yamaha dealer check the vehicle EBU32700 Troubleshooting Although Yamaha vehicles receive an insp...

Page 199: ...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 d...

Page 200: ...aha 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...

Page 201: ...mmended coolant as soon as possible The engine will tend to overheat if the radiator is caked with mud or if air was not properly bled from the cooling system Wait until the engine has cooled Check th...

Page 202: ...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 wa...

Page 203: ...amount of Fuel Med Rx available from your Yamaha dealer or equivalent product Follow the instruc tions on the product label Operate the vehicle for at least 5 minutes to distribute treated fuel throu...

Page 204: ...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 Consu...

Page 205: ...714 0 kg 1574 lb YXZ10YEXR 760 0 kg 1675 lb YXZ10YEZR Loading Maximum load 303 0 kg 668 lb Total weight of operator passenger cargo and accessories Engine Combustion cycle 4 stroke Cooling system Liq...

Page 206: ...L 0 50 US qt 0 41 Imp qt Differential gear oil Type SAE 80W 90 API GL 5 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 56 L 0...

Page 207: ...acturer model MAXXIS M918 BIGHORN YXZ10YEXR MAXXIS ML19A CARNAGE YXZ10YEZR Front brake Type Hydraulic disc brake Rear brake Type Hydraulic disc brake Front suspension Type Double wishbone Rear suspens...

Page 208: ...lated to ex haust emissions as required by federal law state law and Environment Canada EBU38940 Emission Regulation California An add on or modified part must be compli ant with applicable ARB evapor...

Page 209: ...d mileage and 3 other data showing the status of the vehicle such as diagnostic trouble code DTC The collected data will be uploaded to server at Yamaha Motor Co Ltd by attaching a special Yamaha diag...

Page 210: ...uestions or complaints regarding the processing of your vehicle data can be submitted in writing to Yamaha Motor Corporation U S A Attn Privacy Office 6555 Katella Avenue Cypress California 90630 5101...

Page 211: ...purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered i...

Page 212: ...he maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 240 150 15 3 1...

Page 213: ...or inspection and repairs at such dealer s place of business 2 EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of...

Page 214: ...ny later date 3 Each Yamaha Side x Side dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing w...

Page 215: ...to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP give...

Page 216: ...imited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contac...

Page 217: ...rs 5 30 D DC connectors 5 49 Differential gear lock indicator light 5 3 Differential gear oil Periodic maintenance 9 37 Differential gear Pre operation check 6 6 Doors 5 25 Drive mode selecting 7 11 D...

Page 218: ...5 Maintenance chart emission control system 9 3 Maintenance charts 9 3 Maintenance record 12 5 Model label 1 1 Multi function meter unit 5 10 N Neutral indicator light 5 2 Noise regulation for USA 12...

Page 219: ...30 Transmission Pre operation check 6 6 Troubleshooting 9 73 Troubleshooting charts 9 75 U Upper and lower arm pivot lubrication 9 58 Use your vehicle data 12 2 V Valve clearance 9 50 Vehicle Emissio...

Page 220: ...UBDW11E0 book Page 4 Wednesday June 7 2023 11 11 AM...

Page 221: ...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 enginee...

Page 222: ...DIC183 PRINTED IN USA 2023 06 0 6 1 CR E BDWF8199110080 Barcode BDWF8199110080...

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Yamaha YXZ10YEXR, Owner'S Manual

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