brakes YAMAHA YXZ1000R 2016 Owners Manual

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
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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
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5-3
5
EBU31730Front and rear brakesBrake pedal
Check that there is no free play in the brake
pedal. If there is free play, have a Yamaha
dealer check the brake system. (See page
8-47.)
 Check the operation of the brake pedal. It
should move smoothly and there should be
a firm feeling when the brakes are applied.
If not, have the vehicle inspected by a
Yamaha dealer.
Brake fluid level
Check the brake fluid level. Add fluid if neces-
sary. (See page 8-45.) 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 Yamaha dealer.
Brake operation
Check the operation of the brakes at the start
of every ride. Test the brakes at slow speed
after starting out to make sure they are work-
ing properly. If the brakes do not provide
proper braking performance, inspect the
brake system. (See page 8-43.)
EBU35491ClutchClutch pedal
Check the operation of the clutch pedal. The
pedal should move smoothly and there
should be some resistance when the clutch
pedal is depressed.
Specified brake fluid: DOT 4
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7
Eye protection (goggles, helmet face shield,
or protective eyewear)
 Over-the-ankle boots, gloves, long-sleeved
shirt or jacket, and long pants
An approved helmet and other personal pro-
tective equipment can help in a variety of
ways, including:
 Reduce the severity of injuries 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 of impact with
an obstacle or other vehicle.
Wear eye protection when operating or riding
the vehicle to reduce the risk of a serious ac-
cident or injury. Eye protection, such as a face
shield or goggles, may reduce the risk of for-
eign material getting in your eyes and help
prevent loss of vision. Practice for new Yamaha YXZ1000R users
Become familiar with the performance char-
acteristics of the vehicle in a large, flat area
that is free of obstacles and other vehicles.
Practice controlling the accelerator pedal,
clutch, brakes, steering, and shift lever. Drive
at slow speeds with gradual acceleration and
smooth turns. Practice applying the accelera-
tor pedal smoothly. Practice slowing down
before turning. Practice maintaining a steady
amount of throttle (accelerator pedal position)
through the turn. Avoid higher speeds until
you are thoroughly famili
ar 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-
overs.U2HC7LE0.book Page 13 Wednesday, October 7, 2015 12:09 PM

7-15
7
If you think or feel that the vehicle may tip or
roll, keep your body completely inside the
protective structure of the vehicle:
Brace yourself by pressing your feet firmly
on the floorboard and keep a firm grip on
the steering wheel or passenger handhold.
 Do not put your hands or feet outside of the
vehicle for any reason. Do not try to stop a
tipover using your arm or leg.
Accelerating
Avoid higher speeds and sudden or hard ac-
celeration until you are thoroughly familiar
with the operation of your vehicle. Avoid sud-
den or hard acceleration in any turn. Never
drive faster than is safe for current conditions.
Shifting
Follow the instructions on pages 6-2 and 6-3
for shifting, downshifting, and shifting into re-
verse until you are thoroughly familiar with
each operation. Braking
When slowing down or stopping, take your
foot off the accelerator pedal and press the
brake pedal smoothly. Abrupt or 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, partic-
ularly on loose surfaces, such as gravel. Al-
ways allow for greater braking distance on
rough, loose, or slippery surfaces.
Engine compression braking will also help
slow the vehicle down. With the transmission
still in gear, take your foot off the accelerator
and allow the drivetrain and engine to absorb
vehicle speed. Downshift as necessary. Ap-
plication of the brakes provides additional
stopping power.U2HC7LE0.book Page 15 Wednesday, October 7, 2015 12:09 PM

7-19
7
over. Practice 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 traction and
control for climbing steeper and/or rougher
slopes, shift into low gear and select “4WD”
or “DIFF LOCK”. Travel fast enough to main-
tain momentum, but not so fast that you can-
not react to changes in the terrain 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, an
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 at-
tempt to turn the vehicle around. With your
foot on the brake pedal, look behind you and
plan your descent. Press the clutch pedal and
shift the transmission into reverse so you can
use engine braking to slow your descent. Re- lease the brake and clutch, and then begin to
coast down the hill. Use engine braking as
much as possible, gently applying the brakes
when necessary.
Downhill
Check the terrain carefully before going
downhill. When possible, choose a path that
lets you drive your vehicle straight downhill.
Choose your path carefully and drive slowly
enough to be able to react to obstacles that
you encounter.
For more traction and control, before going
down steeper and/or rougher slopes, shift
into low gear and select “4WD” or “DIFF
LOCK”. Engine braking will help you go
downhill slowly. Go as slowly as possible. If
you begin to go too fast, apply the brakes
gently. Avoid hard application of the brakes,
which could cause the vehicle to slide.U2HC7LE0.book Page 19 Wednesday, October 7, 2015 12:09 PM

7-21
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Wet brakes may have reduced effectiveness.
After leaving the water, test your brakes. If
necessary, apply the brakes several times to
let friction dry out the linings.NOTICEECB02950After driving your vehicle in water, be sure
to drain the trapped water by removing the
check hoses at the bottom of the air filter
case. Wash the vehicle in fresh water if it
has been operated in salt water or muddy
conditions. Loose terrain/slippery terrain
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 vehicle in four-wheel
drive before driving on a slippery surface and
plan your path to avoid making abrupt ma-
neuvers. If you feel the vehicle begin to slide sideways
or the back wheels slide during a turn, steer
into the direction of the slide if possible, to re-
gain directional control. For example, if you
feel the back of the vehicle start to slide to
your right, steer to the right.
Brush or wooded areas
When operating in areas with brush or trees,
watch carefully on both sides and above the
vehicle for obstacles such as branches that
the vehicle might hit, causing an accident.
Watch for brush that might enter the vehicle
as you pass and strike you or the passenger.
Never hold onto the cage/frame. The passen-
ger should always hold onto the passenger
handhold with both hands.
The muffler and other engine parts become
extremely hot during operation and remain
hot after the engine has stopped. 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 theU2HC7LE0.book Page 21 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
U2HC7LE0.book Page 44 Wednesday, October 7, 2015 12:09 PM