2016 YAMAHA YXZ1000R clutch

EBU31120
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION......................................... 3-1Left view ............................................... 3-1
Right view ............................................. 3-2
Controls and instruments ..................... 3-3
INSTRUMENT AND CONTROL
FUNCTIONS............................................ 4-1 Main switch .......................................... 4-1
Indicator lights and warning lights ....... 4-2
Multi-function meter unit ...................... 4-6
Light switch ........................................ 4-15
On-Command drive knob “2WD/4WD/DIFF LOCK” .................. 4-15
Reverse gear lock lever “REV.” .......... 4-16
Accelerator pedal ............................... 4-16
Clutch pedal ....................................... 4-17 Brake pedal ........................................ 4-17
Parking brake lever ............................ 4-18
Shift lever ........................................... 4-19
Fuel tank cap...................................... 4-19
Doors .................................................. 4-20
Seats .................................................. 4-20
Adjusting the driver seat position....... 4-22
Adjusting the steering wheel
position ............................................. 4-22
Seat belts ........................................... 4-23
Glove compartment ........................... 4-23
Storage compartments ...................... 4-24
Cup holders ........................................ 4-26
Cargo bed .......................................... 4-27
Flag pole bracket ............................... 4-28
Adjusting the front shock absorber assemblies ....................................... 4-28
Adjusting the rear shock absorber assemblies ....................................... 4-33
Auxiliary DC jack ................................ 4-38U2HC7LE0.book Page 1 Wednesday, October 7, 2015 12:09 PM

FOR YOUR SAFETY –
PRE-OPERATION CHECKS .................... 5-1Front and rear brakes ........................... 5-3
Clutch ................................................... 5-3
Fuel ....................................................... 5-4
Engine oil .............................................. 5-5
Transmission ........................................ 5-6
Coolant ................................................. 5-6
Final gear .............................................. 5-6
Differential gear .................................... 5-7
Accelerator pedal ................................. 5-7
Seat belts ............................................. 5-7
Passenger handhold ............................ 5-7
Steering ................................................ 5-7
Shift lever.............................................. 5-8
Fittings and fasteners ........................... 5-8
Instruments, lights and switches .......... 5-8
Control cables ...................................... 5-8
Tires ...................................................... 5-8
OPERATION ............................................ 6-1 Engine break-in .................................... 6-1
Starting the engine ............................... 6-2 Shift lever operation and reverse
driving .................................................6-3
Selecting the drive mode ......................6-7
Parking ..................................................6-9
Loading .................................................6-9
BASIC GUIDE FOR SAFE USE ...............7-1 KNOW YOUR VEHICLE ........................7-1
LEARNING TO OPERATE YOUR VEHICLE ...........................................7-12
PERIODIC MAINTENANCE AND
ADJUSTMENT .........................................8-1 Owner’s manual and tool kit .................8-2
Periodic maintenance chart for the emission control system .....................8-4
General maintenance and lubrication chart ....................................................8-6
Hood ...................................................8-10
Panels .................................................8-10
Engine oil and oil filter.........................8-15
Transmission oil ..................................8-25
Final gear oil .......................................8-28U2HC7LE0.book Page 2 Wednesday, October 7, 2015 12:09 PM

Differential gear oil ............................. 8-30
Coolant ............................................... 8-33
Axle boots .......................................... 8-34
Checking the spark plugs .................. 8-35
Air filter maintenance.......................... 8-37
Cleaning the air filter case check hoses ................................................ 8-41
Cleaning the spark arrester ................ 8-42
Valve clearance .................................. 8-43
Brakes ................................................ 8-43
Checking the front and rear brake
pads.................................................. 8-44
Checking the parking brake pads ...... 8-44
Checking the brake and clutch fluid levels................................................. 8-45
Brake and clutch fluid replacement ... 8-47
Checking the clutch pedal ................. 8-47
Checking the brake pedal .................. 8-47
Checking the accelerator pedal ......... 8-48
Parking brake lever free play adjustment........................................ 8-49
Brake light switch adjustment ............ 8-50
Cable inspection and lubrication........ 8-50 Pedal lubrication .................................8-51
Checking the stabilizer bushes...........8-51
Upper and lower arm pivot
lubrication (left and right) ..................8-52
Rear knuckle upper and lower pivot
lubrication (left and right) ..................8-53
Drive shaft universal joint lubrication .........................................8-53
Steering shaft lubrication....................8-53
Wheel removal ....................................8-54
Tire replacement .................................8-54
Wheel installation................................8-55
Battery ................................................8-55
Jump-starting .....................................8-59
Fuse replacement ...............................8-60
Headlights...........................................8-62
Headlight beam adjustment ...............8-63
Tail/brake light ....................................8-63
Troubleshooting ..................................8-63
Troubleshooting charts .......................8-65
CLEANING AND STORAGE ....................9-1 Cleaning................................................9-1
U2HC7LE0.book Page 3 Wednesday, October 7, 2015 12:09 PM

3-1
3
EBU31170
DESCRIPTION
EBU31180Left view
1 2,3 4 5 6
10
1178
9
1. Front shock absorber
2. Brake fluid reservoir
3. Clutch fluid reservoir
4. Door
5. Shoulder bolster
6. Driver seat belt
7. Cargo bed
8. Muffler
9. Exhaust pipe
10.Engine 11.TransmissionU2HC7LE0.book Page 1 Wednesday, October 7, 2015 12:09 PM

3-3
3
EBU31200Controls and instrumentsThe vehicle you have purchased may differ slightly from those shown in the figures of this man-
ual.
345
6
7
1
212
10
8,9
13 11
14
1. Steering wheel
2. Reverse gear lock lever
3. Multi-function meter unit
4. Main switch
5. Shift lever
6. Parking brake lever
7. Passenger handhold
8. Helmet indicator light 9. Seat belt indicator light
10.Light switch
11.On-Command drive knob
12.Accelerator pedal
13.Brake pedal
14.Clutch pedalU2HC7LE0.book Page 3 Wednesday, October 7, 2015 12:09 PM

4-17
4
EBU34970Clutch pedalPress the clutch pedal to disengage the
clutch. To engage the clutch, release the
clutch pedal. The clutch pedal should be
pressed rapidly and released slowly for
smooth clutch operation.
EBU31420Brake pedalPress the brake pedal to slow or stop the ve-
hicle.
1. Accelerator pedal
1
1. Clutch pedal
1
U2HC7LE0.book Page 17 Wednesday, October 7, 2015 12:09 PM

4-19
4
EBU34981Shift leverThis model is equipped with a 5-speed se-
quential transmission with reverse gear. The
shift lever is used in combination with the
clutch pedal when shifting. See page 6-3 for
shift lever operation.
EBU31450Fuel tank capTo openRemove the fuel tank cap by turning it coun-
terclockwise.
To closeInstall the fuel tank cap by turning it clock-
wise.
1. Shift lever
1
1. Fuel tank cap
1
U2HC7LE0.book Page 19 Wednesday, October 7, 2015 12:09 PM

5-1
5
EBU31573
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EBU31582Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Own-
er’s Manual.
WARNING
EWB00482Failure to inspect or maintain the vehicle properly increases the possibility of an accident
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. Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
Brakes • Check operation, free play, fluid level, and fluid leakage.
• Fill with DOT 4 brake fluid if necessary. 5-3, 8-43, 8-50
Clutch • Check operation, free play, fluid level, and fluid leakage.
• Fill with DOT 4 brake fluid if necessary. 5-3, 8-47
Parking brake • Check for proper operation, condition, and free play. 8-49
Fuel • Check fuel level.
• Fill with the recommended fuel if necessary. 5-4
U2HC7LE0.book Page 1 Wednesday, October 7, 2015 12:09 PM