2016 YAMAHA YXZ1000R brake

8-7
8
7*Clutch • Check operation and for fluid leakage.
• Correct if necessary. √√√√√
8 *Brake system • Check operation, brake pad wear, and for
fluid leakage.
• Correct if necessary, replace pads if worn to the limit. √√√√√
9 *Parking brake • Check operation and free play/brake pad
wear.
• Correct if necessary. Replace pads if worn to the limit. √√√√√
10 *Brake fluid and
internals • Change the brake fluid.
• Replace internal components of master cyl-
inder and calipers. Every 2 years
11 *Brake hoses • Replace. Every 4 years
12 *Accelerator pedal • Check operation and free play. √√√√√
13 *Reverse lock re-
lease cable • Check operation and adjust or replace if
necessary. √√√
NO. ITEM ROUTINE
INITIAL EVERY
Whichev- er comes first month 1 3 6 6 12
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
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8-9
8
EBU35070TIPInspect and service the vehicle more frequently if you drive aggressively or in severe conditions
such as rain, mud, sand or unusually dusty areas.
 Service the clutch system in similar fashion and at similar intervals to the brake system.
 The service items contained herein should not be considered exhaustive, therefore:
• have your YXZ1000R checked and serviced by your Yamaha dealer at regular intervals.
• replace any damaged or visibly worn part immediately. 21 *Drive shaft uni-
versal joint • Lubricate with lithium-soap-based grease.
√√√
22 *Engine mount • Check for cracks or damage.
• Check bolt tightness.
√√√
23 *Front and rear
axle boots • Check for cracks or other damage, and re-
place if necessary. √√
24 *Fittings and fas-
teners • Check all chassis fittings and fasteners.
• Correct if necessary.
√√√√√
NO. ITEM ROUTINE
INITIAL EVERY
Whichev- er comes first month 1 3 6 6 12
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U2HC7LE0.book Page 9 Wednesday, October 7, 2015 12:09 PM

8-43
8
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 the specified torque.
7. Install the tailpipe cover. 8. Install the bolts and tighten them to the
specified torque.
EBU32460Valve clearanceThe correct valve clearance changes with
use, resulting in improper fuel/air supply or
engine noise. To prevent this, the valve clear-
ance must be adjusted regularly. This adjust-
ment however, should be left to a
professional Yamaha service technician.EBU32470BrakesReplacement of brake components requires
professional knowledge. Brake service
should be performed by a Yamaha dealer.
1. Gasket
2. Spark arrester
3. TailpipeTightening torque:Tailpipe bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2
1
3
Tightening torque:
Tailpipe cover bolt:8 Nm (0.8 m·kgf, 5.8 ft·lbf)
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8-44
8
WARNING
EWB02572Operating with improperly serviced or ad-
justed brakes could lead to a loss in brak-
ing ability and an accident. EBU35150Checking the front and rear brake padsCheck each brake pad for damage and mea-
sure the lining thickness. If a brake pad is
damaged or if the lining thickness is less than
1.0 mm (0.04 in), have a Yamaha dealer re-
place the brake pads as a set.
The wheels need to be removed to check the
brake pads. (See pages 8-54, 8-55 for wheel
removal and installation procedures.)
EBU32490Checking the parking brake padsEach brake pad is provided with a wear indi-
cator groove, which allows you to check the
brake pad wear without having to disassem-
ble the brake. If a brake pad has worn to the
point that the wear indicator groove has al-
most disappeared, have a Yamaha dealer re-
place the brake pads as a set.1. Lining thickness
1
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8-45
8
EBU35160Checking the brake and clutch fluid
levelsBefore starting off, check that the brake and
clutch fluids are above the minimum level
marks. Replenish the brake and clutch fluids
if necessary.
TIPThe brake and clutch fluid reservoirs are lo-
cated under the hood (page 8-10).
 For an accurate reading, make sure the ve-
hicle is parked on a level surface.
1. Parking brake pad wear indicator groove
1
1. Brake fluid reservoir
2. Clutch fluid reservoir
3. Minimum level markSpecified fluid for brake and clutch systems:
DOT 4 brake fluid
3
3 12
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8-46
8
WARNING
EWB03910Improper maintenance can result in loss of
braking ability or clutch operation. Ob-
serve these precautions:
 Insufficient brake or clutch fluid may al-
low air to enter the brake or clutch sys-
tem, reducing braking or 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 rubber seals may deteriorate,
causing leakage.
 Refill with the same type of brake fluid.
Adding a brake fluid other than DOT 4
may result in a harmful chemical reac-
tion. 
Be careful that water or dust does not
enter the brake or clutch fluid reservoir
when refilling. Water will significantly
lower the boiling point of the fluid and
may result in vapor lock.
NOTICEECB01161Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
fluid immediately. As the brake pads wear, it is normal for the
brake fluid level to gradually go down. A low
brake fluid level may indicate worn brake
pads or brake system leakage; therefore, be
sure to check the brake pads for wear and the
brake system for leakage. A low clutch fluid
level may indicate clutch system leakage;
therefore, be sure to check the clutch system
for leakage. If the brake or clutch fluid level
goes down suddenly, have a Yamaha dealer
check and repair the vehicle before any fur-
ther operation.
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8
EBU35170Brake and clutch fluid replacementComplete fluid replacement should be done
only by trained Yamaha service personnel.
Have a Yamaha dealer replace the following
components during periodic maintenance or
when they are damaged or leaking.
 Replace the oil seals every two years.
 Replace the brake and clutch hoses every
four years.EBU35181Checking the clutch pedalThe clutch pedal should operate smoothly
and spring back to position when released.
When depressed, it should offer resistance
before reaching the floorboard. If the pedal
offers little resistance when depressed, or if
the transmission grinds gears when shifting,
have a Yamaha dealer check the vehicle.
TIPDon’t forget to have your Yamaha dealer
check the clutch and transmission as a whole
at the intervals specified in the general main-
tenance and lubrication chart. EBU32530Checking the brake pedalHave a Yamaha dealer check the brakes at
the intervals specified in the periodic mainte-
nance and lubrication chart. There should be1. Clutch pedal
2. No clutch pedal free play
1
2
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8-48
8
no free play in the brake pedal. The brakes
should operate smoothly and there should be
no brake drag. If the brakes feel soft or
spongy, this could indicate air in the brake
system. Have a Yamaha dealer check the
brake system if necessary.
EBU35820Checking the accelerator pedalThe accelerator pedal should operate
smoothly and spring back to position when
released. If the pedal free play is out of spec-
ification, have a Yamaha dealer adjust or re-
place the throttle wire.
1. Brake pedal
2. No brake pedal free play
1
2
Accelerator pedal free play:10.0-25.0 mm (0.39-0.98 in)1. Accelerator pedal
2. Accelerator pedal free play
2
1
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