Page 8 of 188

Hills ................................................ 7-20
Uphill.............................................. 7-21
Downhill ......................................... 7-22
Rough terrain................................. 7-23
Pavement ...................................... 7-23
Water ............................................. 7-23
Loose terrain/slippery terrain......... 7-24
Brush or wooded areas ................. 7-25
Encountering obstacles ................. 7-25
PERIODIC MAINTENANCE AND
ADJUSTMENT .................................. 8-1 Owner’s manual and tool kit ............ 8-2
Periodic maintenance chart for the emission control system .......... 8-4
General maintenance and lubrication chart ............................. 8-5
Hood ................................................ 8-7
Console ........................................... 8-9
Engine oil and oil filter cartridge .... 8-10
Final gear oil .................................. 8-15
Differential gear oil......................... 8-18
Coolant .......................................... 8-22 Axle boots ......................................8-23
Spark plug inspection ....................8-24
Cleaning the air filter element ........8-27
Drive select lever box check
hose .............................................8-32
V-belt cooling duct check hose ......8-32
V-belt case drain plug ....................8-33
Cleaning the spark arrester ...........8-33
Valve clearance .............................8-34
Brakes ............................................8-35
Checking the front and rear brake pads .............................................8-35
Checking the parking brake pads .............................................8-36
Checking the brake fluid level........8-36
Brake fluid replacement .................8-37
Checking the brake pedal ..............8-38
Parking brake lever free play adjustment ...................................8-38
Brake light switch adjustment ........8-40
Cable inspection and lubrication....8-41
Brake pedal and accelerator pedal lubrication.....................................8-41
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3-1
1
23
4
5
6
7
8
9
10
11
12
13
14
EVU00080
1-DESCRIPTION
1. Headlights
2. Front shock absorber assembly
3. Brake fluid reservoir
4. Air filter element
5. V-belt case
6. Driver seat
7. Driver seat belt
8. Cargo bed
9. Tail/brake lights
10. Rear shock absorber assembly
11. Cargo bed release levers
12. Spark plug
13. Door 14. Spark arrester
15. Passenger seat belt
16. Sun top (YXR7FSPD)
17. Passenger seat
18. Passenger handholds
19. Engine oil dipstick
20. Battery
21. Fuses
22. Coolant reservoir
23. Radiator cap
24. Oil filter cartridge
25. Fuel tank cap
CBA 089
IHGF
EJKLM
AC
NO
D
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8-5
EVU01650General maintenance and lubrication chart
ITEMROUTINEWhichever
comes first INITIAL
EVERY
month136612 km
(mi) 320
(200) 1200
(750) 2400
(1500) 2400
(1500) 4800
(3000)
hours 20 75 150 150 300
Cooling system* Check coolant leakage.
Repair if necessary.
Replace coolant every 24 months.
Air filter element
Clean.
Replace if necessary. Every 20–40 hours
(More often in wet or dusty areas.)
Engine oil Replace (warm engine before draining).Engine oil filter cartridge Replace.Final gear oil
Check oil level/oil leakage.
Replace.Differential gear oil
Front brake* Check operation/brake pad wear/fluid leakage/see page 8-6.
Correct if necessary. Replace pads if worn to the limit.Rear brake* Check operation/brake pad wear/fluid leakage/see page 8-6.
Correct if necessary. Replace pads if worn to the limit.Parking brake*
Check operation and free play/brake pad wear.
Correct if necessary. Replace pads if worn to the limit.Accelerator pedal*
Check operation and free play.V-belt* Check operation.
Check for wear, cracks, or damage.Wheels* Check balance/damage/runout.
Repair if necessary.Wheel bearings*
Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension* Check operation and for leakage.
Correct if necessary.Steering system*
Check operation and for looseness/Replace if damaged.
Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots* Lubricate with lithium-soap-based grease.1RB7A_EE.book Page 5 Tuesday, April 24, 2012 9:07 AM
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8-10
5B410012Engine oil and oil filter cartridge
Check engine oil level before each operation.
In addition, change the oil and the oil filter car-
tridge at the intervals specified in the periodic
maintenance and lubrication chart.
To check the engine oil level1. Park the vehicle on a level surface.
2. Remove the console. (See page 8-9 for console removal and installation proce-
dures.)
3. Check the engine oil level on a cold en-
gine. TIPIf the engine was started before checking the
oil level, be sure to warm up the engine suffi-
ciently, and then wait at least 10 minutes until
the oil settles for an accurate reading.4. Remove the engine oil dipstick, and thenwipe it off with a clean rag.
1. Engine oil dipstick
1
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8-12
To change the engine oil (with or without
oil filter cartridge replacement)1. Park the vehicle on a level surface.
2. Remove the console. (See page 8-10 for
console removal and installation proce-
dures.)
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Place an oil pan under the engine to col-
lect the used oil, and then remove the
dipstick.
5. Remove the engine oil drain bolt and its
gasket to drain the oil from the crank-
case.
1. Engine oil drain bolt 2. GasketTIPSkip steps 6–10 if the oil filter cartridge is not
being replaced.6. Lift the cargo bed up. (See pages 4-22– 4-23 for cargo bed lifting and lowering
procedures.)
2
1
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8-13
7. Remove the oil filter cartridge with an oilfilter wrench. Make sure that the O-ring is
removed together with the oil filter car-
tridge. If the O-ring remains attached to
the crankcase, oil leakage may occur.TIPAn oil filter wrench is available from a Yamaha
dealer.1. Oil filter cartridge 2. Oil filter wrench8. Apply a light coat of clean engine oil tothe O-ring of the new oil filter cartridge.
TIPMake sure that the O-ring is properly seated.1. O-ring9. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the
specified torque with a torque wrench.
1
2
Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)
1RB7A_EE.book Page 13 Tuesday, April 24, 2012 9:07 AM
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8-14
1. Oil filter cartridge 2. Torque wrench
10. Lower the cargo bed.
11. Install the engine oil drain bolt and its
new gasket, and then tighten the bolt to
the specified torque. 12. Refill with the specified amount of recom-
mended engine oil, and then insert the
dipstick completely into the oil filler hole.
TIPBe sure to wipe off spilled oil on any parts af-
ter the engine and exhaust system have
cooled down.
Tightening torque:Engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lbf)
1
2
Recommended engine oil: See pages 10-1–10-2.
Oil quantity: Without oil filter cartridge replacement:
2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter cartridge replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt)
1RB7A_EE.book Page 14 Tuesday, April 24, 2012 9:07 AM
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8-30
6. Wash the sponge material gently butthoroughly in parts cleaning solvent.
WARNING! Using gasoline or other
flammable solvents to clean the air fil-
ter element can cause a fire or explo-
sion, which could lead to serious
injury.
7. Squeeze the excess solvent out of the sponge material. NOTICE: Do not twist
the sponge material when squeezing
it. 8. Wash the sponge material in warm soapy
water to remove remaining solvent, then
rinse thoroughly with plain warm water.
9. Squeeze excess water out of the sponge material. NOTICE: Do not twist the
sponge material when squeezing it.
10. Allow the sponge material to dry thor- oughly. Inspect the sponge material and
replace it if damaged.
11. Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil
(not spray type) to the sponge material.
The sponge material should be wet but
not dripping.
12. Pull the sponge material over its frame.
13. Install the air filter element.
1RB7A_EE.book Page 30 Tuesday, April 24, 2012 9:07 AM