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YX Motors YXQUAD X, Manual, Page: 94 / 159

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YX Motors YXQUAD X Manual Download Page 94

Owner’s manual and tool kit

The service information included in this manual is

intended to provide you, the owner, with the nec-

essary information for completing your own pre-

ventive maintenance and minor repairs.

The tools provided in the owners’s tool kit are suf-

ficient for this purpose, except that a torque wrench

is also necessary to properly tighten nuts and

bolts.

8-2

You are recommended to put this owner’s manaul

in the vinyl bag. Put the owner’s tool kit and tire

pressure gauge in the space beside the battery.

1.  Box
2.  Battery

①

②

Summary of Contents for YXQUAD X

Page 1: ...res and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult a dealer INTRODUCTION Please read this manual carefully before operating this vehicle Do not attempt to opertate this vehicle until you have attained adequate knowledge of its controls and operating features R...

Page 2: ...o po tential personal injury hazards Obey all safety messages that follow 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 NOTICE TIP A TIP provides key information to make procedures easier or...

Page 3: ...cident involving other vehicles This vehicle does not meet federal motor vehicle safety standards for on road use Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vheicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations...

Page 4: ...s CONTENTS Seat belts Glove compartment Cargo bed Front and rear shock absorber adjustment Trailer hitch bracket and receiver Auxiliary DC jack FORYOURSAFETYPRE OPERATION CHECKS Front and rear brakes Fuel Engine oil Coolant Final gear oil Differential gear oil Accelerator pedal Seat belts Steering Fitting and fasteners Lights 1 1 2 1 3 1 4 1 4 1 4 2 4 5 4 11 4 13 4 13 4 14 4 15 4 15 4 16 4 16 4 17...

Page 5: ... structure Seat belts Doors Passenger handholds Seat and hip restraints Floorboard Steering wheel LEARNING TO OPERATE YOUR VEHICLE Personal protective equipent Practice for new users Getting ready to ride Turning Acceleration Braking Engine braking Leaving the vehicle Parking on a flat area Parking on a slope Loading Operation on different surfaces and ter rains Hills 5 9 5 9 5 9 6 1 6 1 6 2 6 4 6...

Page 6: ...er element Drive select lever box check hose V belt case drain plug Cleaning the spark arrester Valve clearance Brakes Checking the front and rear brake pads Checking the parking brake pads Brake fluid replacement Checking the brake pedal Parking brake lever free playadjustment Brake light switch adjustment Cable inspection and lubrication Brake pedal and accelerator pedal lubrication Rear knuckle...

Page 7: ...ght bulb Headling beam adjustment Tail brake light bulb replacement Troubleshooting Troubleshooting charts Cleaning and storage A Cleaning B Storage SPECIFICATIONS ELECTRICALCIRCUITDIAGRAM 8 43 8 44 8 45 8 46 8 47 8 51 8 53 8 55 8 56 8 58 8 59 9 1 9 1 9 2 10 1 9 10 11 11 1 Emission Control System Warranty 12 1 12 ...

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Page 12: ...e two chapeters and the labels on the vehicle to instruct new opertators and passengers Do not allow anyone else to operatre your vehicle or ride as a passenger if you are unsure that he she is willing and able to follow these instrucions Get to know your vehicle This off roadvehicle will handle andmaneuver differentlyfrom cars ATVs go carts golf cars and grounds keeping vehicles Follow these inst...

Page 13: ...ly Both driver and passenger must be able to put both feet flat on the floorboard while seated upright with their backs against the seat backs Passenger must be able to reach and hold the handholds within the cage frame Both driver and passenger should wear an approved motorcycle helmet that fits properly Both driver and passenger should also wear eye protection goggles or a face shield gloves ove...

Page 14: ...ng a trailer or pulling objects can affect handling stability and risk of overturn or other accidents Read Chapter 6 before loading towing or pulling objects Do not overload the vehicle or trailer Refer to label in cargo bed for cargo bed load limit Refer to label next to hitch for tongue weight and trailer load limits Keep weight in the cargo bed centered side to side and as low and as far forwar...

Page 15: ... the vehicle can be struck by objects your vehicle is passing or crushed by the vehicle cage frame in a rollover accident Watch for branches brush or other hazards that could enter the vehicle Abrupt maneuver or aggressive driving enven on flat open areas can cause loss of control including rollovers The YXQUAD X has higher ground clearance and other features to handle rug ged terrain and as a res...

Page 16: ...oo far or too fast can result in a rollover Avoid sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn and avoid hard braking in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard acceleration 2 5 ...

Page 17: ...irm grip on the steering wheel or handholds 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 this vehicle on any public street road or highway even if dirt or gravel Do not operate the vehicle in fast flowing water or water deeper than 33 cm 13 in If you must cross shallow ...

Page 18: ...more room to stop Avoid hills and rough terrain Use extreme caution when towing or carrying a load on inclines Load trailer properly and use extra care when towing or pulling Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch if installed 2 7 ...

Page 19: ... yourself Also deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels...

Page 20: ... sold or modifi cations not specifically recommended even if sold and installed by a dealer Aftermarket parts accessories and modifications While you may find aftermarket products similar in design and quality to genuine Accessories series recognize that some aftermarket accessories or modifications are not suitable because potential safety hazards to you or others Installing aftermarket products ...

Page 21: ... tires and rims that came with your X were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate 2 10 YXQUAD ...

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Page 27: ...e On Command four wheel drive indicator comesonwhentheOn Commandfour wheel drive switch is set to the 4WD position The On Command differential gear lock indicator in the On Command four wheel drive indica tor also comes on when the On Command differ ential gear lock switch is set to the LOCK position Due to the synchronizing mechanism in the differential gear case the four wheel drive indi cator m...

Page 28: ...he engine to cool down for about 10 minutes See page 8 60 The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on have a dealer check the electrical circuit NOTICE The engine may overheat if the ve hicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use whi...

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Page 31: ... the hour meter mode HOUR and the voltage displaymode btry in the following order CLOCK HOUR btry CLOCK To set the clock 1 Set the display to the clock 2 Push the Clock Hour button until the clock starts flashing 3 Set the hours by pushing the H button 4 Set the minutes by pushing M button 5 Push the Clock Hour button and then re lease it to start the clock 4 7 ...

Page 32: ...s empty as the fuel level decreases When the empty segment disap pears and the fuel level warning indicator flashes refuel as soon as possible Tip This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective all the display segments and fuel level warning indicator will start flashing If this occurs have a dealer check the electrical circuit 4 8 ...

Page 33: ...ng light switch 7 Right turning light switch Set the switch to OFF to turn off all the lights NOTICE Do not use the headlights with the en gine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it 4 9 ...

Page 34: ...tial gear lock switch 4WD LOCK Select the appropriate drive according to terrain and conditions Two wheel dirve 2WD Power is applied to the rear wheels only Four wheel dirve 4WD Power is applied to the rear wheels and front wheels Four wheel dirve with the differentialgear locked 4WD LOCK Power is supplied to the rear andfront wheels with thedifferential gearlocked Unlike the 4WD mode all wheels t...

Page 35: ...l down to increase en gine speed Spring pressure returns the pedal to the rest position when released Always check that the accelerator pedal returns normallybefore start ing the engine Brake pedal 1 Brake pedal Press the brake pedal to slow or stop the vehicle 4 11 ...

Page 36: ... of the driver s seat It will help keep the vehicle from moving while parked To set the parking brake pull the lever up completely To release the parking brake pull up on the lever press the release button and push the lever all the way down Spring pressure helps return the lever to the re leased position 4 12 ...

Page 37: ...drive select lever is used to shift the vehicle into the low high neutral and reverse positions Refer to pages 6 4 6 5 for the drive select lever operation Fuel tank cap 1 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise 4 13 ...

Page 38: ...ush or pull the door inward unitl is securely latched Be sure the door is SECURELY LATCHEDAFTER CLOSING IT Seats 1 Driver seat 2 Passenger seat 3 Seat lock lever x2 To remove a seat pull its seat lock lever upward lift the front of the seat and then slide the seat forward and up 4 14 ...

Page 39: ...ats are securely latched A loose seat could cause the operator to lose control or cause the operator or passenger to fall Seat belts This vehicle is equipped with three point seat belts for both the operator and the passenger Always wear the seat belts properly when riding in the vehicle See pages 7 6_7 8 more information 4 15 1 Seat Rail Set ...

Page 40: ...in a cup holder Some plastic bottles may not fit into the cup hold ers depending on their size and shape Glove compartment Cup holders While the vehicle is moving do not place any open or glass containers in the cup holders otherwise the contents may spill and the glass con tainers may break Do not place any items other than cups or plastic bottles in the cup holders otherwise they may bethrown ou...

Page 41: ...1 Storage cup holder X1 2 Cup holder X2 Maximum load limit 181 kg 400 lb Cargo bed 1 Cargo bed 2 Tailgate 3 Cargo hook X4 For additional loading information see page 6 9_6 11 4 17 ...

Page 42: ... Place the tailgate in the original position and then hook the latches Lifting and lowering the cargo bed To lift Push down the cargo bed release lever on the left or right side of the vehicle and then slowly lift up the cargo bed until it stops 1 Tailgate 2 Latch X2 1 Cargo bed release lever 4 18 ...

Page 43: ...uit the op erating conditions You can reduce preload for a softer ride or increase preload if frequent bottom ing occurs or when carring loads Always adjust the shock absorbers on the left and right sides to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead an accident NOTICE Frequent or severe bottoming can cause increased wear or damage to the vehi...

Page 44: ...llows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b 1 Special wrench A special wrench can be obtained at a dealer to make this adjustment Standard postion B A Minimum soft E Maximum hard 4 20 ...

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Page 46: ...ries requiring more than the maximum capacity stated above This may overload the circuit and cause the fuse to blow If accessories are used without the engine running the battery will lose its charge and engine starting may become difficult Do not use the automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged NOTICE 4 22 ...

Page 47: ...If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a 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 Check for proper operation condition and free play Parking brake Check fuel level Fill with fuel if necessary C...

Page 48: ... for proper operation and belt wear Seat belts Check for proper operation Check all fittings and fasteners Check tire pressure and for wear and damage Steering Fitting and fasten ers Check for damage Axle boots Check for proper operation L ig ht s an d switches Wheels and tires 5 2 ...

Page 49: ...essary See pages 8 36_8 37 Brake fluid level Recommended brake fluid DOT 4 Brake 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 inspected by a dealer Brake operation Check the operation of the brakes at the start lf every ride Test the brakes at slow speed a...

Page 50: ...tank Wipe up any spilled fuel immediately 1 2 3 4 Be sure the fuel tank cap is closed securely Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gaso...

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Page 52: ...ricates the clutch do not mix any chemi cal additives with oil Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 1 CD specification 2 ENERGYCONSERVINGII Recommeded engine oil type and quan tity See page 10 2 5 6 ...

Page 53: ...ailable add distilled water Change the coolant every two years See pages 8 21_8 22 for details Coolant reservoir capacity up to the maximum level mark 0 32 L 0 28 lmp qt 0 34 US qt Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 16_8 18 for details Final gear oil Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be u...

Page 54: ...Have a dealer repair as ncecessary for proper operation Seat belts A crash can damage the restraint systems in your vehicle Adamaged restraint system may not prop erly protect the person using it resulting in seri ous injury or death in a crash To help make sure your restraint systems are working properly after a crash have them inspected and any necessary replacements made as soon as possible Par...

Page 55: ... in cold weather and you could be unable to control the vehicle Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tires Use the tire pressure gauge to check and adjust tire pressures when the tires are cold Tire pres sures must be equal on both sides Tires pressure Operation of this vehicle with improper tire pressure may cause severe...

Page 56: ...2 9 psi 77 kpa 0 77 kgf cm2 11 psi 98 kpa 0 98 kgf cm2 14 psi 91 kpa 0 91kgf cm2 13 psi 105 kpa 1 05 kgf cm2 15 psi The tire pressure gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the firest reading to be incorrect 1 Tire pressure gauge 5 10 ...

Page 57: ...5 11 1 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Tire wear limit ...

Page 58: ...zero and 20 hours For this reason we ask that you read the follow ing material carefully Because the engine is brand new you must not put an excessive load on it for the first several hours of operation During the first 20 hours the various parts in the engine wear and polish themselves to achieve the correct operatoin clearances During this period prolonged full throttle operation or any conditio...

Page 59: ...ne set throttle position 10 20 hours Avoid prolonged operation above three quarter throttle After break in The vehicle may now be operated normally Starting the engine 1 Turn the main switch to ON NOTICE The coolant temperature warning light and engine trouble warning light should come on then go off If a warning light does not go off see page 4 4 for the corresponding warn ing light circuit check...

Page 60: ...t again Wait a few seconds be fore the next attempt Each attempt should be as short as possible to preserve battery energy NOTICE Do not crank the engine more than 5 seconds on each attempt or starter damage could occur Wait at least 5 seconds between each operation of the electric starter to let it cool Do not turn the key to the START position with the engine running or damage to the electric st...

Page 61: ...tion and reverse driving Shifting neutral to high and high to low 1 Stop the vehicle Take your foot off the accelerator pedal 2 Apply the brake pedal then shift by moving the drive select lever along the shift guide Make sure that the drive select lever is com pletely shifted into position 3 Release the brake pedal and press the ac celerator pedal gradually 1 Drive select lever 6 4 ...

Page 62: ...reverse or vice versa by moving the drive select lever along the shift guide When in reverse the reverse indicator light should be on Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving If the light does not come on ask a dealer to inspect the reverse indicator light electri cal circuit 1 2 3 5 Check behind the vehicle for people or obstacles ...

Page 63: ...vehicle before changing between 2WD and 4WD or 4WD and 4WD LOCK DIFF LOCK 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD 2WD 4WD To change from 2WD to 4WD stop the vehicle and then set the switch to 4WD When the ve hicle is in 4WD the four wheel drive indicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle be sure the differentia...

Page 64: ... LOCK will come on along with the differ ential gear lock indicator in the multi function display To release the differential gear lock stop the vehicle and set the switch to 4WD 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD When the switch is set to LOCK the differ ential gear lock indicator and indicator light will flash until the differential gear is locked When th...

Page 65: ...shing will cause the engine speed to be limited unitl engagement is complete Parking When parking stop the engine and shift the drive select lever into the neutral position Apply the parking brake to help prevent the vehicle from rolling S pages 7 17_7 18 for more information on parking and parking on a slope 6 8 ...

Page 66: ...its for the vehicle see box or vehicle labeling Keep weight in the cargo bed cen tered side to side and as low and as far forward as possible Top heavy loads increase the risk of overturn Be sure cargo is secured a loose load could change handling unexpectedly or strike occupants Do not exceed the Maximum tongue weight Make sure the load does not inter fere with your control or ability to see wher...

Page 67: ... with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Vehicle loading limit total weight of cargo operator passengerandacces sories and tongue weights 367 kg 809 lb Cargo bed 181 kg 400 lb Trailer hitch Pulling load total weight of trailer ...

Page 68: ...ing a load on inclines Turn gradually and go slowly Pulling something other than a trailer We recommends that loads be transported in the bed or in a trailer If you need to move an object a short distance use a winch and follow the winch manufacturer s instructions Improperly pulling can cause serious injury or death Never exceed the Pull ing Load limit of the YXQUAD X Avoid pull ing on inclines I...

Page 69: ...o reduce your risk of an accident and to reduce the risk of serious injury or death in the event of an accident BASIC GUIDE FOR SAFE USE This off road vehicle will handle and maneuver dif ferently from cars ATVs go carts golf cars and grounds keeping vehicles This X has higher ground clearance and other features to handle ruggeed terrain and as a result can overtrun in situations where some vehicl...

Page 70: ...erious injuries or death to drivers or passengers As the owner operator it is your responsibility to protect yourself and your passenger from accidents including rollovers The X has many features including a protective structure and seat belts to help ptotect occupants but the best way to avoid injuries is to avoid accidents There is a risk of injury or death in an accident even with these safety ...

Page 71: ...Remove the ignition key when the vehicle is not in use to prevent unauthorized use of the machine Parents Many states have implemented new motor vehicle licensing requirements for young drivers These requirements are in response to the disproportion ately high rate of crashed involving youthful drivers As with automobiles to promote safe driving behaviors you should supervise younger drivers and c...

Page 72: ...eat Do not carry any other passengers Do not carry passengers in the cargo bed Do not allow someone to ride as a passenger who has been using drugs or alcohol 1 Passenger handhold 2 Seat belt 3 Door This vehicle is designed for the operator and one passenger Carrying passengers improperly can lead to serious injury or death As the operator you are responsible for your passenger Occupant protection...

Page 73: ... serious injury or death You are responsible for any such changes to the vehicle The YXQUAD X 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 features will help protect the occu pants in the event of an accident If these features are not used properly they can cause injury 7 5 ...

Page 74: ...ou think or feel that the vehicle may tip or roll do not put your hands or feet outside the vehicle for any reason You will not be able to stop the vehicle from tipping over using your body Any part of your body arms legs or head outside of the vehicle can be crushed by the vehicle cage frame Seat belts Seat belts should be worn by both driver and passenger Driver must be sure that the passen ger ...

Page 75: ...damage the restraint systems in your vehicle Adamaged restraint system may not prop erly protect the person using it resulting in seri ous injury or death in a crash To help make sure your restraint systems are working properly after a crash have them inspected and any necessary replacements made as soon as possible 1 Seat blet x2 2 Latch plate x2 3 Buckle x2 To wear the seat belt properly do the ...

Page 76: ...atch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 2 3 Put the lap portion of the belt low on your hips Pull up on the shoulder part so the belt is snug across your hips Position the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it loose pull the belt out all the way and then let it retract To ...

Page 77: ...struck by objects or crushed against outside objects or the ground during a rollover Passenger handholds Handholds are provided to trip during opeartion to maintain proper position and balance Holding onto the handholds helps to reduce the likelihood that the passenger puts a hand outside the vehicle if the vehicle begins to tip There are two handholds on the protective structure and two handholds...

Page 78: ...t and hip restraints are designed to help keep you in the vehicle Do not hold onto hip re straint bar when the vehicle is moving Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover ...

Page 79: ...s inside the rim Keep your palms on the outside of the steering wheel Similar to other offroad vehicles if the Rhino hits a deep rut or large obstacle the steering wheel could briefly jerk in one direction or back and forth as the tires and vehicle respond to the obstacle This quick motion could injure your thumbs or wrist if your thumbs or hand s are in side the steering wheel Grip the steering w...

Page 80: ...Personal protective equipment 1 Approved motorcycle helmet 2 Eye protection 3 Long sleeved shirt or jacket 4 Gloves 5 Long pants 6 Over the ankle boots LEARNING TO OPERATE YOUR VEHICLE 7 12 ...

Page 81: ...acle Wear eye protection when operation or riding the vehicle to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision You should become familiar with the performance characteristics of the vehicle in a large flat area that is free of obstacles and other vehicles P...

Page 82: ...e with the differential locked DIFF LOCK Steering may take more effort in 4WD with the differential locked DIFF LOCK Also practice driv ing in reverse Take the time to learn basic operation of the ve hicle before attempting more difficult maneuvers Perform the Pre Operation Checks on pages 5 1_5 11 Follow the instructions starting on pages 6 2_6 3 to start the engine 7 14 ...

Page 83: ... sideways or fishtail during a turn steer into the direction of the slide if possible and gradually let off the accel erator pedal to regain 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 your body completely inside the protective structure of the vehic...

Page 84: ... Braking When slowing down or stopping take your foot off the accelerator pedal and press the brake pedal smoothly 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 application of the brakes is more effective than abrupt braking particular...

Page 85: ...at area When parking on a flat area stop the engine and shift the drive select lever into the neutral position Apply the parking brake to help prevent the ve hicle from rolling Parking on slope The parking brake acts only on the rear wheels when in 2WD For the parking brake to take effect on four wheel shift to 4WD Diff Lock before stop ping the engine If you park on a hill that is too steep the v...

Page 86: ...is ve hicle may handle differently in certain types of ter rains or on certain surfaces You may come upon hidden rocks bumps or holes without enough time to react To avoid loss of control or rollover always be alert to changing surfaces or terrain when op eration the vehicle The YXQUAD X has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situati...

Page 87: ...ng techniques to avoid rearward forward or sideways rollovers on hills and slopes If you think or feel the YXQUAD X may tip or roll Brace yourself by pressing your feet firmly on thefloorboardsandkeepa firm griponthesteer ing wheel or handholds Do not put your hands or feet outside of the vehicle for any reason Drive straight up and down inclines not across them If crossing a hill is unavoidable d...

Page 88: ... maintain momentum but not so fast that you can not react to changes in the ter rain as you climb Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person and obstacle or a sharp drop off If you start to lose traction or momentum when climbing and decide you will be unable to continue use the brakes to stop Do not attempt to t...

Page 89: ...as slowly as possibe If you begine to go too fast apply the brakes gently Avoid hard application of the brakes which could cause the vehicle to slide If you are sliding or skidding try to steer in the direction the vehicle is sliding to regain control For example if you feel the back of the vehicle start to slide to your right steer to the right If you must turn on the hilll to avoid an obstacle d...

Page 90: ...oorboards choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause the vehicle to overturn Never operate through water deeper than 33 cm 13 in or fast flowing water Chosse a path where both your entrance into and exit point from the water is a gradual incline De termine the water depth and currents before crossing Operating this vehicle through deep or ...

Page 91: ... When driving on slippery terrain including wet muddy or icy conditions as well as loose gravel be aware that you could begin skidding or sliding To avoid loss of control slow down and put the YXQUADX in 4WD before driving on a slippery sur face and plan your path to avoide making abrupt maneuvers If you feel the X begin to slide sideways or fishtail during a turn steer into the direction of the s...

Page 92: ... under the vehicle after operationg in areas where combustile mate rials may have collected Do not idle or park the vehicle in long dry grass or other dry ground cover Encountering obstacles If you cannot go around an obstacle such as a fallen tree or a ditch stop the vehicle where it is safe to do so Set the parking brake and ge out to inspect the area thoroughly Look from both your approach side...

Page 93: ...ay increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle service have a dealer per form service PERIODIC MAINTENANCE AND ADJUSTMENT Turn off the engine when performing maintenance unless other wise specificed A running enging has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires R...

Page 94: ...wn pre ventive maintenance and minor repairs The tools provided in the owners s tool kit are suf ficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts 8 2 You are recommended to put this owner s manaul in the vinyl bag Put the owner s tool kit and tire pressure gauge in the space beside the battery 1 Box 2 Battery ...

Page 95: ...If you do not have a torque wrench available during a service operation requiring one take your ve hicle to a dealer to check the torque settings and adjust them as necessary 8 3 ...

Page 96: ...should be performed by a dealer as they require special tools data and techincal skills Check fuel hose for cracks or damage Replace if necesary Check valve clearnace Adjust if necessary Check condition Adjust gap and clean Replace if necessary Check breather hose for cracks or damage Replace if necessary Check for leakage Tighten if necessary Replaxe gasket s if necessary Clean EVERY Fuel line Va...

Page 97: ... brake pad wear Correct if necessary Replace pads if worn to the limit Check operation and free play Check operation Check for wear cracks or damage Check balance damage runout Repair if necessary EVERY Cooling Air filter element Engine oil Engine oil filter car tridge Final gear oil Differential gear oil 6 2 400 1 500 150 12 4 800 3 000 300 3 1 200 750 75 6 2 400 1 500 150 1 320 200 20 ITEM ROUTI...

Page 98: ... rear suspension Steering system Rear upper and lower knuckle pivots 6 2 400 1 500 150 12 4 800 3 000 300 3 1 200 750 75 6 2 400 1 500 150 1 320 200 20 ITEM ROUTINE INITAIL month km mi hours Whichever comes first Drive shaft univer sal joint Engine mount Front and rear axle boots Stabilize bushings Fitting and fasten ers Recommended brake flud DOT 4 Brake fluid replacement Replace the brake fluid ...

Page 99: ...1 Latch x2 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 2 Hood 8 7 ...

Page 100: ...atched or removed To close Lower the hood slowly to its original positon and then hook the hood latches Secure projections 1 on the rear of the hood into slots 2 on the back of the instrument panel Secure slots 3 on the side of the hood around projections 4 on the frame 1 Projection x2 2 Slot x2 3 Slot x2 4 Projection x2 8 8 ...

Page 101: ... the edge of the hole in the console Console 1 Remove the seats See page 4 16_4 17 for seat removal and installation procedures 2 Remove the parking brake lever boot 3 Pullthe consoleforward and upward the drive select lever boot will come loose To ease re moval of the console shift the drive select lever into the low gear L position 1 Console To remove 1 Place the console in its original position...

Page 102: ...k the engine oil level 1 Park the vehicle on a level surface 2 Remove the console See page 8 9 for con sole removal and installation procedures 3 Check the engine oil level on a cold engine If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the dipstick and then...

Page 103: ...it again to check the oil level The engine oil should be between the mini mum and maximum level marks 6 If the engine oil is at or below the minimum levelmark addsufficientoilof therecommended type to raise it to the correct level 7 Insert the dipstick completely into the oil filler hole 8 Reinstall the console 8 11 ...

Page 104: ...ation procedures 3 Start the engine warm it up for several minutes and then turn off 4 Place an oil pan under the engine to collect the used oil and then remove the dipstick 5 Remove the engine oil drain bolt to drain the oil from the crankcase Skip steps 6 10 if the filter cartridge is not being replaced 6 Lift the cargo bed up See pages 4 20_4 21 for cargo bed lifting and lowering procedures 8 1...

Page 105: ...e If the O ring remains attached to the crankcase oil leakage may occur 8 Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge Make sure the O ring is seated properly 1 O ring 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft l...

Page 106: ...tridge replacement 2 00 L 1 76 lmp qt 2 11 US qt With oil filter cartridge replacement 2 10 L 1 85 lmp qt 2 22 US qt Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf 12 Refill with the specified amount of recom mended engine oil and then insert the dipstick completely into the oil filler hole NOTICE Be sure to wipe off spill oil on any parts after the engine and exhaust system hav...

Page 107: ...e oils labeled EN ERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 13 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 14 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 15 Reinstall the conso...

Page 108: ...hould be at the brim of the filler hole Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf NOTICE Be sure to no foreign material enters the final gear case Checking the final gear oil lever 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 Reinstall the oil fillter bolt and then tighten it to the spec...

Page 109: ...ning torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain bolt to drain the oil 5 Reinstall the drain bolt and then tighten it to the specified torque 1 Final gear oil drain bolt 8 17 1 Final gear case guard 2 Bolt and collar x4 ...

Page 110: ...ar case 7 Reinstall the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 8 Check for oil leakage If oil leakage is found check for the cause 9 Install the final gear case guard by installing the bolts and the collars and then tightening teh bolts to the specified torque Tightening torque Final gear case guard bolt 7 ...

Page 111: ...ntial gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Differential gear oil 1 Park the vehicle on a level surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the specified level 1 Differential gear oil filler bolt 2 Correct oil level 3 Differential gear oil Checking the differential g...

Page 112: ...ifferential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 18 L 016 lmp qt 0 19 US qt 6 Refill the differential gear case with the rec ommended oil 7 Reinstall teh differential gear oil filler bolt and then tighten it to the specified torque NOTICE Be sure ...

Page 113: ... each ride Coolant Checking the coolant level 1 Park the vehicle on a level surface 2 Check the coolant level in the coolant reser voir when the engine is cold as the coolant level varies with engine temperature The cool ant should be between the minimum and maxi mum level marks 8 21 FULL LOW 3 If the coolant is at or below the minimum level mark remove the reservoir cap add cool ant to the maximu...

Page 114: ...hanging the coolant NOTICE Mix antifreeze with distilled water only However if distilled water is not available soft water may be used for refilling If you vehicle overheats see page 8 60 for instructions 8 22 Screw off the water tank cap A and the engine exhaust vent bolt B put in some antifreeze Do not screw on the bolt B until antifreeze spill out from the exhaust vent Start the engine let it w...

Page 115: ...Check the protective boots for holes or tears If any damage is found have them replaced by a dealer Axle boots 1 Front axle boot x2 each side 1 Rear axle boot x2 each side 8 23 ...

Page 116: ... 8 9 for con sole removal and installation procedures 2 Remove the spark plug cap Spark plug inspection 1 Spark plug cap Removal 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plug Wrench 8 24 ...

Page 117: ... center electrode is a medium to light tan for a vehicle that is being ridden normally You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break dwon and erode If carbon and other deposits are excessive you should replace the spark plug with the specified plug Inspection a Spark plug gap Installation Spark plug gap 0 8 0 9 mm 0 03...

Page 118: ...ter to one half turn past finger tight Have the spark plug tightened to the specified torque as soon as possible Tightening torque Spark plug 12 5 Nm 1 25m kgf 9 0 ft lbf 4 Install the spark plug cap 5 Reinstall the console There is a check hose at the bottom of the air filter case and at the bottom of the air duct under the case If dust or water collects in a check hose empty the hose and clean t...

Page 119: ...e check hose 1 Open the hood See pages 8 7_8 8 for hood opening and closing procedures 2 Remove the air intake duct shroud by remov ing the quick fastener screws 1 Quick fastener screw x2 2 Air intake duct shroud 8 27 ...

Page 120: ...1 Air filter case cover holder x5 2 Air filter case cover 3 Remove the air filter case cover by unhook ing the holders 1 Air filter element 4 Remove the air filter element 8 28 ...

Page 121: ... gently but thor oughly in parts cleaning solvent NOTICE Do not twist the sponge material when squeezing it Using gasoline or other flammable sol vents to clean the air filter element can cause a fire or explosion which could lead to serious injury 7 Squeeze the excess solvent out of the sponge material 8 29 ...

Page 122: ...lace it if damaged 11 Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge be wet but not dripping 12 Pull the sponge material over its frame 13 Reinstall the air filter element 14 Insert the projections on the air filter case cover into the holder on the air filter case and then install the air filter case cover by hooking the holders onto ...

Page 123: ...ered air entering the engine NOTICE Never operate the engine with the air filter element removed This will al low unfiltered air to enter causing rapid engine wear and possible en gine damage Additionally operation without the air filter element will af fect the fuel injection system with subsequent poor performance and possible engine overheat 1 Drive select lever box check hose Drive select leve...

Page 124: ... 17 for seat removal and installation procedures After riding in water deep enough to allow water to enter the V blet case remove the drain plug to drain any water from the case If water drains from the V belt case after removing the drain plug have a dealer inspect the vehicle as the water may affect other engine parts 8 32 ...

Page 125: ...emove the bolts 2 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 3 Gasket 4 Install the gasket and then insert the tailpipe into the muffler and align the bolt holes 5 Insta...

Page 126: ... pro fessional knowledge Brake service should be per formed by a dealer Operating with improperly serviced or adjusted brakes could lead to a loss in braking ability and an accident Checking the front and rear brake pads Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the we...

Page 127: ...cedures Each brake pad is provided with two wear indica tor grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indi cator grooves If a brake pad has worn to the point that a wear indicator groove almost appears have a dealer replace the brake pads as a set 1 Brake pad wear indicator groove 8 35 ...

Page 128: ...servoir is located under the hood See pages 8 7_8 8 for hood opening and closing procedures Observe these precautions When checking the fluid level make sure the top of the brake fluid reservoir is level Use only the recommended quality brake fluid Otherwise the rubber seals may deteriorate causing leakageand poorbrakingperformance Recommended brake fluid DOT 4 Refill with the same type of brake f...

Page 129: ...nents during periodic mainte nance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years Checking the brake pedal Have a dealer check the brakes at the intervals specified in the periodic maintenance and lubrica tion chart There should be no free play in the brake pedal The brakes should operate smoothly and there should be no brake drag...

Page 130: ...nd installation procedures 3 Remove the console See page 8 9 for con sole removal and installation procedures 4 Check the parking brake lever free play The maximum free play is equal to one click of the parking brake lever If necessary adjust the free play as follows 5 The parking brake lever must be released when checking and adjusting the parking brake lever free play 6 Loosen locknut a Parking ...

Page 131: ... by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Open the hood See pages 8 7_8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in di rection a To make the brake ...

Page 132: ...k a dealer to replace them Damaged cables could restrict operation which may cause an accident or injury Inspect control cables fre quently and replace damaged cables Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Recommended lubricant Lithium soap based grease 8 40 ...

Page 133: ...r Brake pedal and accelerator pedal Lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease Rear knuckle upper and lower pivot Lubrication 1 Remove the lower arm protector by removing the bolts 8 41 ...

Page 134: ...grease 2 Lubricate the knuckle upper and lower piovts with a grease gun 2 Install the lower arm protector by installing the bolts and tightening them to the specified torque Tightening torque Lower arm protector 7 Nm 0 7 m kgf 5 1 ft lbf 8 42 ...

Page 135: ... based grease Lubricate the pivot points Steering shaft lubrication 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 Wheel removal 1 Nut x4 8 43 ...

Page 136: ...best combination of handing 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 pairs front or rear with tires of the same size and type as the original Never replace just one tire Tire replacement Installing improper tires on your YXQUAD X can affect handling and stability This can cause a loss of control 8 44 ...

Page 137: ...install the wheel and the nuts 1 Arrow mark The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their ta pered side towards the wheel 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque 1 Tappered nut 8 45 ...

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Page 139: ...t prompt medial attention Batteries may produce explosive gases Ventilate when charging or using in a closed space Keep batteries away from sparks flames cigarettes or other sources of ignition NOTICE A special battery charge constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery lift Battery maint...

Page 140: ...1 Negative battery lead black 2 Positive battery lead red 8 48 ...

Page 141: ...e any material in place of the proper fuse Using an im proper fuse can cause damage to the electrical system and may lead to a fire 1 Remove the quick fastener screws 2 Remove the battery compartment cover by lifting it up and pulling it out 1 Quick fastener screw x3 2 Battery compartment cover Turn the key to OFF and turn off the electrical circuit in question NOTICE To prevent accidental short c...

Page 142: ...tion fuse Auxiliary DC jack fuse Signaling system fuse Four wheel drive motor fuse Radiator fan fuse Backup fuse 40 0 A 10 0 A 15 0 A 10 0 A 10 0 A 10 0 A 10 0 A 25 0 A 10 0 A 4 Trun the key to ON and turn on the electri cal circuit in question to check if the device operates 5 If the fuse blows again immediately have a dealer check the electrical system 6 Reinstall the battery compartment cover b...

Page 143: ...ows Replacing a headlight bulb 1 Lift the hood up See pages 8 7_8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 8 51 3 Remove the headlight bulb holder by pulling it in and turning it counterclockwise 1 Headlight bulb holder ...

Page 144: ...ing it in 1 Do not touch the glass of the bulb 8 52 7 Reinstall the bulb holder by pushing it in and turning it clockwise Reinstall the bulb holder cover and the cover at the rear of the headlight NOTICE Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 8 Close the hood 9 Adjust the headlight beam if necessary ...

Page 145: ...Headlight beam adjustment 1 Headlight beam adjusting screw NOTICE It is advisable to have a dealer make this adjustment To raise the beam or to lower the beam turn the adjusting screw 8 53 ...

Page 146: ...8 54 ...

Page 147: ... bulb in and turn if counter clockwise to remove it from the bulb holder 6 Push a new bulb in and turn it clockwise to install in the bulb holder 7 Reinstall the bulb holder together with the bulb by turning it clockwise 8 Install the panel 9 Lower the cargo bed 10 Reinstall the quick fastener screws and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 7 Nm 0 7...

Page 148: ...to a dealer The skilled technicians at a dealer ship have the tools experience and know how to properly ser vice your vehicle Use only genuine parts on your vehicle Imitation parts but they are often inferior Consequently they have a shorter service lift and lead to expensive repair bills When checking the fuel system do not smoke and make sure there are no open flames or sparks in the area includ...

Page 149: ...Troubleshooting charts Starting problems or poor engine performance 8 57 ...

Page 150: ...or cap hot fluid and steam could blow out under pressure and burn you Place a thick rag over the cap and remove the cap slowly to allow any remaining pressure to escape If it is difficult to get the recommended coolant tap water can be used temporarily provided that it is changed to the recommended coolant as soon as possible 8 58 ...

Page 151: ...have reduced stopping ability increasing the chance of an accident A Cleaning Frequent thorough cleaning of your vehicle will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the vehicle a Block off the end of teh exhause pipe to to prevent water entry A plastic bag and strong rubber band may be used b Make sur...

Page 152: ...rfaces Avoidcom binationcleaner waxes Manycontain abrasives which may scratch the paint or protective finish When finished start the engine and let it idle for several minutes B Storage Long term storage 60 days or more of your ve hicle will require some preventive procedures to guard against deterioration Make any necessary repairs before store the vehicle After thoroughly cleaning the vehicle pr...

Page 153: ...xhaust pipe out let to prevent moisture form entering 6 If storing in a humid or salt air atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 7 Remove the battery and charge it Store it in a dry place and recharge if once a month Do not store the battery in an excessively warm or cold place less than 0o c 30 0 F or more than 3...

Page 154: ...ke 4 valve SOHC water oil cooled 87 5mmx82mm 10 3 1 25kw 6000rpm 45Nm 5000rpm BSR36 CDI Electric starter L H N R Shaft drive CHASSIS Suspension Front Suspension Rear Brakes Front Brakes Rear Tires Front Tires Rear Independent double swing arm Independent double swing arm Dual ventilated hydraulic disc Dual ventilated hydraulic disc AT25 x8 12 radial AT25x10 12 radial ...

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