Yamaha PRO HAULER 1000, PRO HAULER 700 User Manual

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READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YXP700

YXP1000

JW4-F8199-10LIT-11626-17-54

INTRODUCTION

Congratulations on your purchase of the Yamaha YXP700/YXP1000. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features 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 Yamaha dealer.

WARNING

Please read this manual carefully before operating this vehicle. Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operating features. Regular inspections and careful maintenance, along with good operating techniques, will help ensure that you safely enjoy the capabilities and reliability of this vehicle.

IMPORTANT MANUAL INFORMATION

WARNING

CAUTION:

NOTE:

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the utility vehicle occupants, a bystander, or a person inspecting or repairing the utility vehicle.

This message describes special precautions that must be taken to avoid damage to the utility vehicle.

This message provides additional key information.

NOTE:

●

Yamaha continually seeks advancements in product design and quality; therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your utility vehicle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

●

This manual should be considered a permanent part of your utility vehicle and should remain with the car when resold.

WARNING

Read and understand this manual completely before operating your utility vehicle.

IMPORTANT NOTICE

●

This vehicle is designed and manufactured for off-road use only. It is illegal to operate this machine on any public street, road, or highway. Such use is prohibited by law.

●

Check the laws and regulations in force before choosing where to operate this vehicle. It is illegal to operate this vehicle on public lands where vehicles its size are prohibited.

YXP700/YXP1000

OWNER’S MANUAL

AFFIX DEALER

LABEL HERE

U.S.A.

permission of

Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11626-17-54

CONTENTS

LOCATION OF THE WARNING

AND SPECIFICATION LABELS....... 1-1

DESCRIPTION AND VEHICLE

IDENTIFICATION ............................. 2-1

Features .......................................... 2-1

Utility vehicle serial number............. 2-2

Key identification number................ 2-2

SAFETY INFORMATION.................. 3-1

CONTROL FUNCTIONS .................. 4-1

Main switch...................................... 4-1

Oil level warning light ...................... 4-2

Fuel tank cap................................... 4-2

Drive select lever............................. 4-3

Accelerator pedal ............................ 4-4

Brake pedal .....................................4-4

Parking brake pedal ........................ 4-5

Starter (choke)................................. 4-5

Auxiliary DC jack ............................. 4-6

Cargo bed ........................................4-7

Trailer hitch bracket .......................4-11

PRE-OPERATION CHECKS ............5-1

Pre-operation check list ...................5-2

Brakes..............................................5-3

Fuel ..................................................5-4

Engine oil .........................................5-5

Transmission oil...............................5-5

Accelerator pedal.............................5-6

Steering............................................5-6

Fittings and fasteners ......................5-6

Lights................................................5-6

Switches...........................................5-6

Tires .................................................5-7

OPERATION .....................................6-1

Starting a cold engine ......................6-1

Starting a warm engine....................6-3

Stopping...........................................6-3

Accessories and loading..................6-4

DRIVING YOUR VEHICLE............... 7-1

Getting to know your vehicle........... 7-1

Learning to operate your vehicle .... 7-3

Turning your vehicle........................ 7-3

Braking ............................................ 7-3

Going uphill ..................................... 7-4

Going downhill................................. 7-5

Crossing through shallow water...... 7-6

Rough terrain .................................. 7-7

Riding in brush or wooded areas.... 7-7

PERIODIC MAINTENANCE AND

ADJUSTMENT ................................. 8-1

Owner’s manual .............................. 8-1

Periodic maintenance/

lubrication...................................... 8-3

Exhaust emission control system

and components ........................... 8-5

Seat................................................. 8-6

Cargo bed ....................................... 8-6

Spark plug inspection...................... 8-8

Engine oil ........................................ 8-9

Air filter element cleaning.............. 8-12

Drive belt........................................ 8-14

Battery ...........................................8-15

Fuse replacement.......................... 8-16

Transmission oil............................. 8-17

Wheel removal............................... 8-18

Wheel installation ..........................8-19

Brake adjustment...........................8-20

Brake pedal free play

adjustment ...................................8-20

Replacing a headlight bulb............ 8-22

Adjusting a headlight beam........... 8-23

Replacing a taillight bulb ...............8-24

CLEANING AND STORAGE ............ 9-1

Draining the fuel ..............................9-1

Engine preparation .......................... 9-1

Chassis preparation ........................ 9-2

Battery preparation.......................... 9-2

SPECIFICATIONS ..........................10-1

MAINTENANCE RECORD............. 11-1

YAMAHA MOTOR

CORPORATION, U.S.A. VEHICLE LIMITED

WARRANTY .................................. 12-1

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................... 13-1

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle.

Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.

YXP700

1-1

1-2

YXP700

Do not temper with governor to increase speed. Operation at higher speeds can cause loss of control that can result in severe injury or death.

Ne pas toucher au r égulateur afin d ’augmenter la vitesse. Un fonctionnement à des vitesses supé rieures au r églage initial peut causer une perte de contrô le qui peut mener à une blessure grave, voire fatale.

YAMAHA JN3-K8299-10

WARNING AVERTISSEMENT

YAMAHA JU7-F1696-00

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE

LOSS OF CONTROL.

LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR

DEATH.

OPERATING TIRE PRESSURE: Set with tires cold.

RECOMMENDED: 84 kPa, {.84 kgf/cm}, 12 psi MINIMUM: 70 kPa, {.70 kgf/cm}, 10 psi

Never set tire pressure below minimum. Tire may

dislodge from rim.

Vehicle Rated Capacity: 700 lb (318 kg)

maximum including weight of operator, passenger, accessories, cargo, and (if applicable) trailer tongue weight.

OFF

• Gasoline is

extremely flammable.

• Keep heat, sparks

and open flame away from fuel tank and fuel lines.

• Do not add fuel

while engine is running or hot.

• Do not modify fuel

system. Service should be performed by dealer or qualified personnel.

OIL

WARNING

JU7-K7761-00YAMAHA

• L’essence est

exstrêmement inflammable.

• Garder étincelles, flammes

et chaleur loin du ré servoir à essence et des tuyaux à carburant.

• Ne pas ajouter d’essence

pendant que le moteur est en marche ou quand le moteur est chaud.

• Ne pas modifier le système

d’ alimentation. Toute ré vision doit être faite chez le fournisseur ou par du personnel qualifié.

Improper use can result in SEVERE INJURY or DEATH

• Vehicle capacity: 1 operator and 1 passenger.

• Remain seated and hold on while in motion.

• This vehicle is recommended only for operators 16 and older

with a valid motor vehicle license. Adults must supervise use by minors. Check state laws for minimum age requirements.

• Drive slowly in turns.

• Drive straight up and down hills-driving across the side of a

hill increases the risk of overturn.

• Keep entire body inside vehicle.

• Passenger and cargo can affect vehicle handling.

• Vehicle rated capacity (driver, passenger, cargo, trailer, and

load) 700 lb. (318 kg) on level surface.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safety standards applicable to passenger cars.

USE REGULAR UNLEADED GASOLINE ONLY

Motor Oil Requirements:

• Use only SAE

• Maintain oil

YAMAHA JN3-K8297-10

10W-30, API service SE or SF.

level between dipstick “MIN” and “MAX” marks.

ATTENTION

UTILISER UNIQUEMENT DE L’ESSENCE SANS PLOMB

Pour l’huile du moteur, il faut:

• Utiliser uniquement SAE 10W-30, API service SE ou SF.

• Garder le niveau d’huile entre les marques “MIN” et “MAX” indiquées sur la jauge de niveau d’huile.

1-3

WARNING

Keep hands, body, other persons away when closing bed.

Do not operate the vehicle

YAMAHA 5UG-K7764-00

with bed up.

Severe INJURY or DEATH can result if you ignore the following:

• Maximum Load in Cargo Bed: 250 lb. (113 kg).

• Never carry passengers or fill fuel containers in cargo bed.

• Cargo can affect handling and stability. Read Owner’s Manual before loading or towing.

• When loading with cargo or towing a trailer: Reduce speed and allow more room to stop.

Avoid hills and rough terrain.

• Be sure cargo is secured—a loose load could change handling unexpectedly.

• Keep weight in the cargo bed centered, and as low and far forward as possible.

Top-heavy loads increase the risk of overturn.

YAMAHA

WARNING

JU7-K7766-01

Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury. Never load more than 68 kg (150 lbs) tongue weight on the towing bracket. Do not tow more than 227 kg (500 lbs) rolling weight (trailer plus cargo). Allow for increased braking distance and use extreme caution when operating on inclines. Read carefully the loading information and trailer hitch sections in the owner’s manual.

YAMAHA JU7-K7768-00

ENGINE AIR INDEX (California only)

0 2 4 6 8 10

MOST CLEAN LEAST CLEAN

NOTE : THE LOWER THE AIR INDEX. THE LESS THE POLLUTION THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT FOR THE FOLLOWING USE :

MODERATE

CHECK OWNERS MANUAL FOR FURTHER DETAILS

THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY

INTERMEDIATE

EXTENDED

1-4

YXP1000

1-5

YXP1000

YAMAHA JU9-F1696-00

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE

LOSS OF CONTROL.

LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR

DEATH.

OPERATING TIRE PRESSURE: Set with tires cold.

RECOMMENDED: 84 kPa, {.84 kgf/cm}, 12 psi MINIMUM: 70 kPa, {.70 kgf/cm}, 10 psi

Never set tire pressure below minimum. Tire may

dislodge from rim.

Vehicle Rated Capacity: 1000 lb (454 kg)

maximum including weight of operator, passenger, accessories, cargo, and (if applicable) trailer tongue weight.

OFF

Severe INJURY or DEATH can result if you ignore the following:

• Maximum Load in Cargo Bed: 500 lb. (227 kg).

•

Never carry passengers or fill fuel containers in cargo bed.

•

Cargo can affect handling and stability. Read Owner’s Manual before loading or towing.

• When loading with cargo or towing a trailer: Reduce speed and allow more room to stop.

Avoid hills and rough terrain.

• Be sure cargo is secured—a loose load could change handling unexpectedly.

• Keep weight in the cargo bed centered, and as low and far forward as possible.

Top-heavy loads increase the risk of overturn.

YAMAHA

WARNING

YAMAHA 5UG-K7764-00

WARNING

Keep hands, body, other persons away when closing bed.

Do not operate the vehicle with bed up.

WARNING

Improper use can result in SEVERE INJURY or DEATH

• Vehicle capacity: 1 operator and 1 passenger.

• Remain seated and hold on while in motion.

• This vehicle is recommended only for operators 16 and older

with a valid motor vehicle license. Adults must supervise use by minors. Check state laws for minimum age requirements.

• Drive slowly in turns.

• Drive straight up and down hills-driving across the side of a

hill increases the risk of overturn.

• Keep entire body inside vehicle.

• Passenger and cargo can affect vehicle handling.

OIL

• Vehicle rated capacity (driver, passenger, cargo, trailer, and load) 1000 lb. (454 kg) on level surface.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safety standards applicable to passenger cars.

JU9-K7761-00YAMAHA

ATTENTION

JU9-K7766-01

1-6

Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury. Never load more than 68 kg (150 lbs) tongue weight on the towing bracket. Do not tow more than 454 kg (1000 lbs) rolling weight (trailer plus cargo). Allow for increased braking distance and use extreme caution when operating on inclines. Read carefully the loading information and trailer hitch sections in the owner’s manual.

YAMAHA JU5-K7768-00

ENGINE AIR INDEX (California only)

0 2 4 6 8 10

MOST CLEAN LEAST CLEAN

NOTE : THE LOWER THE AIR INDEX. THE LESS THE POLLUTION THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT FOR THE FOLLOWING USE :

MODERATE

CHECK OWNERS MANUAL FOR FURTHER DETAILS

THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY

INTERMEDIATE

EXTENDED

1-7

DESCRIPTION AND VEHICLE IDENTIFICATION

FEATURES

1. Steering wheel

2. Seat

3. Battery

4. Taillight

5. Rear tire

6. Fuel tank

7. Drive select lever

8. Starter (choke)

9. Front tire

10. Front bumper

11. Headlight

12. Accelerator pedal

13. Brake pedal

14. Parking brake pedal

15. Auxiliary DC jack

16. Main switch

17. Oil level warning light

2-1

Utility vehicle serial number

The utility vehicle serial number is stamped in the location shown.

NOTE:

The first three digits of the serial number are for model identification; the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer.

Key identification number

The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.

1. Key identification number

2-2

SAFETY INFORMATION

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

●

Read this manual and all labels carefully and follow the operating procedures described.

●

This vehicle is designed to carry the driver and one passenger. Never carry passengers in the cargo bed.

●

Never give a ride to a passenger who is unable to put both feet firmly on the floorboard while seated with his or her back against the backrest. The passenger must hold on to the grab rail at all times while the vehicle is in motion.

●

Never operate this vehicle on any public street, road, or highway, even a dirt or gravel one.

●

Never consume alcohol or drugs before or while operating this vehicle.

●

Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, and operating conditions, and your experience.

●

Never attempt jumps or other stunts.

●

Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

●

Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard.

●

Always keep both hands on the steering wheel when driving.

3-1

●

Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when driving the vehicle.

●

Never operate on excessively rough, slippery, or loose terrain.

●

Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at faster speeds. Do not attempt turns on steep slopes.

●

Never operate the vehicle on slopes that are too steep for it or for your abilities. Go straight up and down slopes where possible.

●

Never operate on slopes that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a slope at speed if you cannot see what is on the other side.

●

Always check terrain carefully before going down slopes. Go as slowly as possible. Never go down a slope at high speed.

●

Always check for obstacles before operating in a new area.

●

Never operate the vehicle in fast flowing water or water deeper than 15 cm (6 in). Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

●

Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Do not brake abruptly when carrying loads in the cargo bed.

●

Always use the size and type of tires specified in this manual.

●

Always maintain proper tire pressure as described in this manual.

3-2

●

Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible, and distributed evenly from side to side. Be sure cargo is secured so that it cannot move around during operation. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

3-3

CONTROL FUNCTIONS

Main switch

The main switch positions are as follows:

OFF: All electrical circuits are switched off. The key can be removed in this position only.

ON: All electrical circuits (except for the headlights and taillights) are switched on. The utility vehicle can be operated. ON : All electrical circuits are switched on. The headlights and taillights come on. The utility vehicle can be operated.

4-1

Oil level warning light

This warning light comes on when the engine oil level is low.

If the light comes on, stop the engine, check the engine oil level, and add oil as necessary. (See page 8-9–8-10).

Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

1. Fuel tank cap

1. Oil level warning light

CAUTION:

Always make sure there is enough engine oil before starting the engine.

4-2

Drive select lever

The drive select lever is used for driving the utility vehicle either forward or in reverse. After coming to a complete stop, shift the lever to the desired position.

Lever position Vehicle movement

FFORWARD

R REVERSE

NOTE:

The back-up buzzer will sound when the drive select lever is shifted to “R.”

4-3

Accelerator pedal

The accelerator pedal controls the utility vehicle’s speed.

Action Vehicle speed

Depress pedal Increase Release pedal Decrease

1. Accelerator pedal

NOTE:

The engine does not start until the accelerator pedal is depressed.

Brake pedal

Press the brake pedal down to slow or stop the utility vehicle.

1. Brake pedal

NOTE:

The engine stops when the utility vehicle comes to a complete stop.

4-4

Parking brake pedal

Press the parking brake pedal down whenever parking the utility vehicle.

1. Parking brake pedal

NOTE:

Release the parking brake by depressing the accelerator pedal.

Starter (choke)

Pull the starter (choke) knob out and hold it when starting a cold engine. Release it after the engine starts.

1. Starter (choke) knob

4-5

Auxiliary DC jack

The auxiliary DC jack is located in the front panel. The auxiliary DC jack can be used for accessories such as lights, radios, etc. The auxiliary DC jack should only be used for short periods if the utility vehicle is not being operated.

1. Auxiliary DC jack cap

1. Set the main switch to “ON”.

2. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack.

1. Auxiliary DC jack

Maximum rated capacity for the auxiliary DC jack:

DC 12 V, 120 W (10 A)

3. Close the auxiliary DC jack cap if the jack is not being used.

4-6

CAUTION:

Do not use accessories requiring

●

more than the maximum rated capacity for the auxiliary DC jack. This may overload the circuit and cause the fuse to blow. If accessories are used for extended

●

periods when the utility vehicle is not being operated or with the main switch set to “ON ”, the battery will lose its charge and starting the engine may become difficult. Do not use an automotive cigarette

●

lighter or other accessories with a plug that get hot because the jack can be damaged.

Cargo bed

1. Cargo bed

4-7

Opening and closing the tailgate (For YXP1000)

1. Tailgate 2. Latch (× 2)

To open: Unhook the latches, and then lower the tailgate. To close: Place the tailgate in its original position, and then hook the latches.

Lifting and lowering the cargo bed

1. Cargo bed release lever

4-8

1. Prop rod

To lift: Pull the cargo bed release lever towards the rear, and then slowly lift up the cargo bed until end of the prop rod hooks onto the prop rod guide to support the cargo bed. To lower: Slightly lift up the cargo bed, unhook the end of the prop rod, and then lower the cargo bed slowly to its original position. Make sure that the latch for the cargo bed is properly engaged.

Maximum load limit:

113 kg (250 lb) (YXP700) 227 kg (500 lb) (YXP1000)

WARNIN G

POTENTIAL HAZARD Overloading the cargo bed. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated maximum load for this cargo bed. Cargo should be properly distributed. Reduce speed when carrying cargo. Allow greater distance for braking.

4-9

WARNIN G

POTENTIAL HAZARD Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall, be thrown out, or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger. This cargo bed is designed to carry cargo only.

POTENTIAL HAZARD Pinch point. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame or the seat backs when the bed is being lowered. HOW TO AVOID THE HAZARD Before closing the cargo bed, be sure others are standing away from the utility vehicle and that no one is sitting on the seat. Keep hands and fingers away from the space between the cargo bed and seat backs.

4-10

WARNIN G

POTENTIAL HAZARD Fire or explosion while filling a portable fuel container. WHAT CAN HAPPEN Static electricity sparks can ignite fuel vapors. The plastic bed is not grounded, increasing the risk of static electricity build-up. HOW TO AVOID THE HAZARD Do not refill fuel containers in the plastic bed. Set fuel container on the ground and touch the nozzle to the container before removing the container cap. Keep nozzle in contact with can inlet when filling. Tighten cap before putting fuel container in cargo bed.

Trailer hitch bracket

This vehicle is equipped with a 5 cm (2 in) receiver bracket for a standard trailer hitch.

Trailer towing equipment can be obtained at a Yamaha dealer. (See page 6-5 for precaution information.)

1. Trailer hitch bracket

4-11

PRE-OPERATION CHECKS

Pre-operation checks should be made each time you use your utility vehicle. Get in the habit of performing the following checks in the same way so that they become second nature.

WARNIN G

POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle.

WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD Always inspect 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 Owner’s Manual.

5-1

Pre-operation check list

Before using this vehicle, check the following points:

ITEM ROUTINE PAGE

Brakes

Parking brake

Fuel

Engine oil

Transmission oil

Accelerator pedal

Steering

Fittings and fasteners

Lights and switches

Wheels and tires

• Check for proper operation, condition and free play. 5-3, 8-20–8-22

• Check fuel level.

• Fill with fuel if necessary.

• Check oil level.

• Fill with oil if necessary.

• Check for leakage. 5-5, 8-17–8-18

• Check for proper accelerator pedal operation. 5-6

• Check for proper operation. 5-6

• Check all fittings and fasteners. 5-6

• Check for proper operation. 5-6, 8-22–8-24

• Check tire pressure, wear and damage. 5-7–5-9, 8-18–8-19

5-4–5-5

5-5, 8-9–8-10

5-2

Brakes Brake pedal

Check for correct brake pedal free play. If the brake pedal free play is incorrect, have a Yamaha dealer adjust it. (See pages 8-20– 8-22.) 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 operation

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake system. (See pages 8-20–8-22.)

WARNIN G

POTENTIAL HAZARD Driving with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not operate the vehicle if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.

5-3

Fuel

Make sure there is sufficient gasoline in the tank.

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

24.0 L (5.3 Imp gal, 6.3 US gal) (YXP700)

30.0 L (6.6 Imp gal, 7.9 US gal) (YXP1000)

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.

Gasohol

There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems.

5-4

WARNIN G

POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely.

Engine oil

Make sure that the engine oil is at the specified level. Add oil if necessary. (See pages 8-9–8-10 for details.)

CAUTION:

Make sure that no foreign material enters the crankcase.

Recommended engine oil type and quantity:

See page 10-3.

Transmission oil

Make sure the transmission oil is at the specified level. Add oil as necessary. (See pages 8-17–8-18 for details.)

Recommended oil:

SAE 90 gear oil

5-5

Accelerator pedal

Remove the key from the main switch. Make sure that the accelerator pedal operates properly. It must operate smoothly and fully spring back when released. If the accelerator pedal does not operate properly, have a Yamaha dealer check the pedal.

WARNIN G

POTENTIAL HAZARD Checking operation of the accelerator pedal with the key in the main switch.

WHAT CAN HAPPEN The engine can start and the vehicle can start moving when the accelerator pedal is depressed. HOW TO AVOID THE HAZARD Remove the key from the main switch before checking accelerator pedal operation.

Steering

Park on level ground. Turn the steering wheel to the right and left. Check for excessive free play, abnormal noises, or a rough feeling. If the steering does not operate properly, have a Yamaha dealer check the steering.

Fittings and fasteners

Always check the tightness of chassis fittings and fasteners before a ride. Take the utility vehicle to a Yamaha dealer or refer to the Service Manual for the correct tightening torques.

Lights

Check the headlights and taillights to make sure they are in working condition. Repair as necessary for proper operation.

Switches

Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.

5-6

Tires Checking the tire pressure

Use a tire pressure gauge to measure the tire pressure.

NOTE:

Measure the tire pressure twice and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

WARNIN G

POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD

1. The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model. Other tire combinations are not recommended.

YXP700

Manufacturer Size

Front DURO 20 × 10-8 / 4 PLY

Rear DURO 20 × 10-8 / 4 PLY

5-7

YXP1000

Manufacturer Size

Front DURO 22 × 11-10 / 6 PLY

Rear DURO 22 × 11-10 / 6 PLY

2. The tires should be set to the recommended pressure:

●

Recommended tire pressure Front 84 kPa (0.84 kgf/cm Rear 84 kPa (0.84 kgf/cm

, 12 psi)

, 12 psi) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides.

3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums:

Front 70 kPa (0.70 kgf/cm Rear 70 kPa (0.70 kgf/cm

, 10 psi)

4. Use no more than the following pressures when seating the tire beads.

Front 250 kPa (2.5 kgf/cm Rear 250 kPa (2.5 kgf/cm

, 36 psi)

, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.

5-8

Tire wear limit

When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.

a. Tire wear limit

5-9

OPERATION

Starting a cold engine

1. With the parking brake applied, shift the drive select lever to “F” for forward, or “R” for reverse.

CAUTION:

Do not shift from “F” forward to “R” re- verse while the utility vehicle is moving.

2. Turn the main switch to “ON” or “ON ”.

WARNIN G

POTENTIAL HAZARD Depressing accelerator pedal while turning on the main switch.

WHAT COULD HAPPEN The utility vehicle could start moving unexpectedly. HOW TO AVOID THE HAZARD Keep foot away from accelerator pedal while turning on the main switch.

6-1

3. Pull the starter (choke) knob out and hold

it while starting a cold engine. Release the starter (choke) knob after the engine starts.

4. Check that your path is clear in the direction you plan to go, and slowly depress the accelerator pedal. The engine will start and the utility vehicle will start to move.

1. Starter (choke) knob

NOTE:

The choke is not required when the engine is warm.

1. Accelerator pedal

NOTE:

The parking brake automatically releases when the accelerator pedal is depressed.

6-2

Starting a warm engine

To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. Press the accelerator pedal slightly.

Stopping

To stop the utility vehicle, gradually press down on the brake pedal. When the utility vehicle has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.”

1. Brake pedal 2. Parking brake pedal

CAUTION:

Do not hold the utility vehicle on an incline with the accelerator – use the brake.

6-3

Accessories and loading

Accessories

Accessories can affect the handling and control of your vehicle. Keep the following in mind when considering an accessory or operating a vehicle which has accessories.

●

Choose only accessories designed for your vehicle. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality.

●

Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are operating could affect your ability to control the vehicle.

●

Do not mount an accessory where it could interfere with your ability to control the vehicle. Examples include (but are not limited to) an object that limits your ability to turn the steering wheel or one that limits your view.

●

Use extra caution when driving a vehicle with accessories. The vehicle may handle differently than it does without accessories.

6-4

EBU09600

Cargo or a trailer can change the stability and handling of a vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind:

●

Never exceed the weight limits shown. An overloaded vehicle can be unstable.

MAXIMUM LOADING LIMIT

●

Maximum cargo bed load: 113 kg (250 lb) (YXP700) 227 kg (500 lb) (YXP1000)

●

Tow hitch Tow weight (Including driver, passenger, vehicle cargo and trailer and trailer cargo): 227 kg (500 lb) (YXP700) 454 kg (1000 lb) (YXP1000) Tongue weight: 68 kg (150 lb)

●

Choose a trailer hitch drawbar designed for use with a 5 cm (2 in) receiver. (See page 4-11 for more information.)

●

Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale 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.

●

Load cargo in the cargo bed as close to the center of the vehicle as possible.

●

Tie down cargo securely in the trailer. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident.

6-5

●

Make sure the load does not interfere with controls or your ability to see where you are going.

●

Drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer.

●

Allow more braking distance. A heavier vehicle takes longer to stop.

●

Avoid making sharp turns unless at very slow speeds.

●

Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the vehicle.

WARNIN G

POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.

6-6

DRIVING YOUR VEHICLE

WARNIN G

GETTING TO KNOW YOUR VEHICLE

This off-highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle.

Before you begin to use your vehicle, be sure you have read this Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 3-1–3-3. Please also read all caution and warning labels on your vehicle. This vehicle is designed for the operator and one passenger. Never carry passengers in the cargo bed.

POTENTIAL HAZARD Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed. The cargo bed is designed to carry cargo only.

7-1

Carrying a passenger and cargo can affect vehicle handling. The total weight of operator, passenger, accessories, cargo, trailer tongue weight, and the vehicle itself must not exceed the maximum load limit.

Maximum load limit:

318 kg (700 lb) (YXP700) 454 kg (1000 lb) (YXP1000)

WARNIN G

Remain seated and hold on when the vehicle is in motion. Keep hands and feet inside the vehicle at all times.

7-2

LEARNING TO OPERATE YOUR VEHICLE

You should become familiar with the performance characteristics of the vehicle in a large, flat area that is free of obstacles and other vehicles. Practice control of the accelerator, brakes, steering, and forward/reverse select lever. Drive first at slow speed and become comfortable at that speed before gradually increasing your speed. Take the time to learn basic operation before attempting more difficult maneuvers. Set the parking brake. Perform the Pre-Operation Checks on pages 5-2. If the engine is cold, pull out the choke knob. To start the engine, press the accelerator pedal slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle. Push in the choke knob after the engine has warmed.

When slowing down or stopping, take your foot off the accelerator pedal and smoothly press the brake pedal. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident. The engine stops running when the vehicle stops.

TURNING YOUR VEHICLE

It is possible for the vehicle to roll over or go out of control if you attempt sharp, higher speed turns. You should also be careful making sharp turns on rough terrain. Do not attempt to turn around or make abrupt maneuvers on slopes.

BRAKING

Braking ability is affected by the type of terrain. In most cases, gradual application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces.

7-3

GOING UPHILL

Do not attempt to climb slopes until you have mastered basic maneuvers on flat ground. Use proper driving techniques to avoid overturns on hills and slopes. Drive straight up slopes, and avoid crossing the side of a slope, which increases your chance of rollover. Practice first on gentle inclines before attempting slopes. Always check the terrain carefully before attempting any slope. Use common sense and remember that some slopes are too steep for you to climb.

Maximum slope angle:

15°

Choose carefully which slopes you attempt to drive on. Avoid slopes with slippery surfaces or ones where you will not be able to see far enough ahead of you.

WARNIN G

POTENTIAL HAZARD Operating on steep slopes. WHAT CAN HAPPEN The utility vehicle can overturn more easily on steep slopes than on level surfaces or gentle inclines. HOW TO AVOID THE HAZARD Never operate your vehicle on slopes too steep for it or your abilities. Never operate vehicles on slopes steeper than 15°. Do not drive across the face of a slope. Go straight up the slope. Practice on smaller slopes before attempting large slopes.

Slow down when you reach the crest of the hill if you cannot clearly see what is on the other side - there could be another person, an obstacle, or a sharp drop off.

7-4

If you start to lose traction or momentum when going up a slope, and you decide you will be unable to continue, use the brakes to come to a stop. Do not attempt to turn the vehicle around. Instead, back down the hill as slowly as possible, gently applying the brakes when necessary.

GOING DOWNHILL

Check the terrain carefully before going down a slope. When possible, choose a path that lets you drive your vehicle straight downhill. Carefully choose your path and drive no faster than you will be able to react to obstacles that may appear. If you must turn to avoid an obstacle, do not turn at a sharp angle that could allow the vehicle to pitch or roll over.

WARNIN G

POTENTIAL HAZARD Going down a slope improperly. WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any slope. Never go down a slope at high speed. Avoid going down a slope at an angle that would cause the vehicle to lean sharply to one side. Go straight down the slope where possible.

Go as slowly as possible. If you are starting to go too fast, apply the brakes gently. Avoid sudden application of the brakes, which could cause the vehicle to start sliding. If you start to slide or skid, try to steer in the direction the vehicle is sliding to help you regain control.

7-5

If you must turn on the slope to avoid an obstacle, do so slowly and carefully. If the vehicle starts to tip, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you want to go.

CROSSING THROUGH SHALLOW WATER

If you must cross shallow, slow moving water up to 15 cm (6 in), 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 15 cm (6 in) or fast flowing water. 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.

WARNIN G

POTENTIAL HAZARD Operating this vehicle through deep or fast-flowing water. WHAT CAN HAPPEN Loss of control, which could result in an accident including overturn. HOW TO AVOID THE HAZARD Never operate the vehicle in fast flowing water or in water deeper than 15 cm (6 in). Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

7-6

ROUGH TERRAIN

Avoid operating over very rough terrain. Look for obstacles that could cause damage to the vehicle or could lead to a rollover or accident. Avoid jumping the vehicle as injury, loss of control, and damage to the vehicle could occur.

WARNIN G

POTENTIAL HAZARD Operating in rough terrain.

WHAT CAN HAPPEN The vehicle can overturn or go out of control.

HOW TO AVOID THE HAZARD Always be alert to changing terrain. Go slowly and be extra careful on unfamiliar terrain, so you will have enough time to react to hidden rocks, bumps, or holes in your path.

RIDING IN 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, or for brush that might enter the vehicle as you pass and strike the driver or passenger.

7-7

EBU05150

PERIODIC MAINTENANCE AND

ADJUSTMENT

Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner. The most important points of vehicle inspection, adjustment and lubrication are explained on the following pages.

WARNIN G

POTENTIAL HAZARD Servicing an engine while it is running.

WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine and remove the main switch key when performing maintenance unless otherwise specified.

Have a Yamaha dealer perform service if you are not familiar with vehicle service.

EBU05620

Owner’s manual

You are recommended to put this owner’s manual in the vinyl bag and always keep it with the vehicle. The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs.

NOTE:

If you do not have a torque wrench available during a service operation requiring one, take your vehicle to a Yamaha dealer to check the torque settings and adjust them as necessary.

8-1

WARNIN G

POTENTIAL HAZARD Operating this vehicle with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha vehicle dealer.

8-2

PERIODIC MAINTENANCE/LUBRICATION

NOTE:

● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.

● For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in

mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.

ITEM ROUTINE

Valves*

Spark plug

Air filter element and pre-air filter element

Carburetor*

Exhaust system*

Fuel line*

Engine oil

Transmission oil

Brakes*

Accelerator pedal*

V-belt*

Whichever

comes first

• Check valve clearance.

• Adjust if necessary.

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

• Clean.

• Replace if necessary.

• Check starter operation.

• Adjust if necessary.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Check fuel hose for cracks or damage.

• Replace if necessary.

• Replace (warm engine before draining).

• Check oil level/oil leakage.

• Replace. Every 4 years

• Check operation/brake shoe wear.

• Correct if necessary. Replace shoes if worn to the limit.

• Check operation and free play.

• Check operation.

• Check for wear, cracks, or damage.

month 1 6 6 12

(mi)

hours 20 125 125 250

INITIAL EVERY

160

(100)

1,000 (600)

Every 20–40 hours

(More often in wet or dusty areas.)

1,000 (600)

8-3

2,000

(1,200)

ITEM ROUTINE

Wheels*

Wheel bearings*

Front and rear suspension*

Steering system*

Engine mounts*

Fittings and fasteners*

* Since these items require special tools, data and technical skills have a Yamaha dealer perform the service.

• Check balance/damage/runout.

• Repair if necessary.

• Check bearing assemblies for looseness/damage.

• Replace if damaged.

• Check operation and for leakage.

• Correct if necessary.

• Check operation and for looseness/Replace if damaged.

• Check toe-in/Adjust if necessary.

• Check for cracks or damage.

• Check bolt tightness.

• Check all chassis fittings and fasteners.

• Correct if necessary.

Whichever

comes first

month 1 6 6 12

(mi)

hours 20 125 125 250

INITIAL EVERY

160

(100)

1,000

(600)

1,000 (600)

2,000

(1,200)

8-4

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS

Item Acronym

●

CARB. ASSY., LH., JT., CARBURETOR

CARB (Carburetor)

2 & JT., CARBURETOR 1

●

T.C.I. MAGNETO ASSY. & PLUG, SPARK El (Electronic Ignition)

●

CRANKCASE 1 & HEAD, CYLINDER 1 PCV (Positive Crankcase Ventilation)

●

AIR FILTER ASSY. ACL (Air Cleaner)

●

MUFF., 2

The above items and the corresponding acronyms are provided in accordance with U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULATIONS FOR NEW 1995 AND LATER OFF-HIGHWAY RECREATIONAL VEHICLES AND ENGINES.

The acronyms conform to the latest version of the SAE’s recommended practice document J1930, “Diagnostic Acronyms, Terms, and Definitions For Electrical/Electronic System”.

It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.

8-5

Seat

Lift the seat to check the fuel level and add fuel. To service the engine for the YXP700, the seat must be lifted.

1. Seat 2. Prop rod

Cargo bed

Lift the cargo bed to service the engine for the YXP1000.

1. Pull the cargo bed release lever towards the rear.

2. Lift the cargo bed.

3. Lift the cargo bed up until the end of the prop rod hooks onto the prop rod guide to support the cargo bed.

1. Cargo bed release lever

8-6

1. Prop rod

WARNING

Remove the key from the main switch

●

and apply the parking brake before lifting the cargo bed. Otherwise, the utility vehicle could move unexpectedly. Never operate the utility vehicle with

●

the cargo bed in the up position. Injury could occur if the cargo bed falls accidentally. Before closing the cargo bed, be sure

●

others are standing away from the utility vehicle and that no one is sitting on the seat. Keep hands and fingers away from the space between the cargo bed and seat backs.

8-7

Spark plug inspection

Periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor engine performance.

1. Spark plug 2. Spark plug cap

1. Check for discoloration and heavy carbon deposits. The normal electrode color will be tan. If it is not, replace it.

2. Check the spark plug type, and check the spark plug gap with a feeler gauge.

Specified spark plug:

BPR2ES (NGK)

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

a. Spark plug gap

8-8

3. Clean the gasket and plug surfaces and install the spark plug, and then tighten it to the specified torque.

Spark plug torque:

20 Nm (2.0 m·kgf, 14.5 ft·lbf)

WARNING

When removing or installing the spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.

Engine oil Checking the engine oil level

1. Place the utility vehicle on a level surface.

2. Lift the seat (YXP700) or cargo bed (YXP1000). (See page 8-6–8-7 for lifting and lowering procedures.)

3. Remove the dipstick, wipe it off with a clean rag, and then insert the dipstick back into the dipstick hole.

1. Dipstick

8-9

NOTE:

Insert the dipstick into the crankcase until it firmly seats in place.

4. Remove the dipstick and check the oil level.

MIN

MAX

1. Dipstick

2. Maximum level mark 3. Minimum level mark

5. The oil level should be between the maximum and minimum marks. If the level is low, add oil to raise it to the specified level.

CAUTION:

Be sure no foreign material enters the crankcase.

Replacing the engine oil

1. Place the utility vehicle on a level surface.

2. Place a container under the engine.

3. Remove the engine oil filler cap and engine oil drain bolt to drain the oil.

1. Engine oil filler cap

8-10

1. Engine oil drain bolt

NOTE:

●

The engine oil can be drained quickly if the utility vehicle has been operated for several minutes to warm up the engine before changing the oil.

●

Dispose of used oil in an environmentally safe manner, such as taking oil to an oil collection station.

4. Install the drain bolt along with a new drain bolt gasket, and then tighten it to the specified torque.

Tightening torque:

Drain bolt:

30 Nm (3.0 m·kgf, 22 ft·lbf)

5. Add the specified amount of engine oil, and then install the oil filler cap.

Recommended oil:

See page 10-3.

Oil change quantity:

0.9 L (0.79 Imp qt, 0.95 US qt)

CAUTION:

Be sure no foreign material enters the crankcase.

8-11

6. Operate the utility vehicle for several minutes to warm up the engine, and then check for oil leakage.

CAUTION:

If oil leakage is found, check for the cause.

Air filter element cleaning

To remove the air filter elements:

1. Unlatch the air filter cover holders and remove cover.

2. Lift the air filter element and pre-air filter element out of the air filter case.

1. Air filter element

2. Pre-air filter element

CAUTION:

Be careful not to drop anything into the air inlet.

1. Air filter cover holders 2. Air filter cover

8-12

Inspection and cleaning:

3. Wash the pre-air filter element in soap and water. Allow it to dry.

1. Soap and water 2. Pre-air filter element

CAUTION:

Do not wring out the pre-air filter element, this could cause it to tear.

4. Check the air filter element. If damaged or dirty, replace it.

CAUTION:

Do not attempt to clean the air filter element with compressed air. It could be damaged.

5. To replace the elements, reverse the above steps.

CAUTION:

The “UP” mark on the pre-air filter element should face up.

8-13

Drive belt

To remove the drive belt:

1. Set the drive select lever halfway between forward and reverse.

2. Pull up on the drive belt and push it outward over the edge of the secondary sheave.

3. Turn the secondary sheave clockwise and the drive belt will roll off the sheave.

Y-60

Inspection: To inspect the drive belt, check for frayed edges or tears, and measure the drive belt as shown. If the belt shows excessive wear or damage or if it reaches the wear limit of 27.9 mm (1.10 in), replace the belt with a new one.

a. Wear limit

5. To install the drive belt, reverse the above steps.

4. Remove the drive belt from the primary sheave.

NOTE:

Roll the drive belt over the secondary sheave when installing.

8-14

Battery

WARNING

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

The battery doesn’t require the addition of water. If the battery loses its charge, have an experienced mechanic charge it.

8-15

Fuse replacement

The fuses are located under the driver’s side of the seat for the YXP700 and the passenger’s side of the seat for the YXP1000. (See page 8-6 for seat opening and closing procedures.) If a fuse is blown, replace it.

WARNING

Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and create a fire hazard.

CAUTION:

When replacing a fuse be sure the main switch is turned off to prevent accidental short-circuiting.

1. Main fuse 2. Auxiliary DC jack fuse

3. Headlight/signaling system fuse

Replacement Fuse:

Main fuse: 20 A Headlight/signaling system fuse: 10 A Auxiliary DC jack fuse: 10 A

8-16

Transmission oil Transmission oil measurement

1. Place the vehicle on a level surface.

2. Remove the transmission oil filler plug 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 recommended type to raise it to the specified level.

1. Transmission oil plug

CAUTION:

Be sure no foreign material enters the transmission case.

3. Install the transmission oil filler plug.

Recommended oil:

SAE 90 gear oil

Oil quantity:

0.42 L (0.37 Imp qt, 0.44 US qt)

8-17

4. Check for oil leakage. If oil leakage is found, check for the cause.

NOTE:

For transmission oil replacement, consult a Yamaha dealer.

Wheel removal

To remove and install a wheel on your utility vehicle:

1. Nut (× 4)

1. With the wheels blocked to prevent the utility vehicle from moving, loosen the wheel nuts.

2. Elevate the utility vehicle with a jack and remove the wheel nuts.

3. Remove the wheel.

8-18

Wheel installation

1. Install the wheel and the nuts.

NOTE:

●

Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel.

●

The arrow mark on the tire must point toward the rotating direction of the wheel.

1. Arrow mark

1. Tapered nut

2. Lower the vehicle so that the wheel is on the ground.

3. Tighten the wheel nuts to the specified torque.

Wheel nut torque:

Front: 80 Nm (8.0 m·kgf, 58 ft·lbf) Rear: 80 Nm (8.0 m·kgf, 58 ft·lbf)

8-19

Brake adjustment

The brakes on your utility vehicle are self-adjusting.

Before you operate the car, press down on the brake pedal several times to make sure the brakes are functioning properly.

WARNING

Consult your Yamaha dealer before using your utility vehicle if you suspect brake problems. Brake failure could result in a serious accident.

Brake pedal free play adjustment

CAUTION:

Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes.

To adjust the brake pedal free play:

1. Remove the service lid from the floor of the utility vehicle.

Y-61a

8-20

2. Check the brake pedal free play by pressing against the pedal with two fingers (using light force) and measuring the distance the pedal travels before resistance is felt.

Brake pedal free play:

20–25 mm (0.79–0.98 in)

3. If the free play distance needs adjusting, loosen the locknut and turn the adjusting nut in or out (in 180° increments only, due to the cam shape of adjuster), until the free play specification is met. Then tighten the locknut to the specified torque.

YXP700

a. Brake pedal free play

1 5 1

1 3 1

121

1. Locknut 2. Adjusting nut

8-21

YXP1000

1. Locknut 2. Adjusting nut

Tightening torque:

17 N·m (1.7 m·kgf, 12 ft·lbf)

WARNING

Do not overtighten the adjusting nut or locknut. The self adjusters may not operate properly, reducing braking performance.

Replacing a headlight bulb

If a headlight bulb burns out, replace it as follows.

1. Remove the headlight bulb holder by turning it counterclockwise.

1. Headlight bulb holder

2. Remove the defective bulb by unhooking the headlight bulb holder tabs.

8-22

1. Headlight bulb holder tab (× 2)

3. Insert a new headlight bulb into the bulb holder, and then hook the headlight bulb holder tabs.

4. Install the headlight bulb holder by turning it clockwise.

Adjusting a headlight beam

CAUTION:

It is advisable to have a Yamaha dealer make this adjustment.

To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b.

1. Headlight beam adjusting screw

8-23

Replacing a taillight bulb

If a taillight bulb burns out, have a Yamaha dealer replace it.

8-24

CLEANING AND STORAGE

Perform the following preparations when storing your utility vehicle for extended periods of time:

NOTE:

Turn main switch key to “OFF” position, remove key, and store key in a safe place.

Draining the fuel

1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or equivalent product. Operate the utility vehicle for at least 5 minutes to distribute treated fuel through the fuel system.

2. Drain the carburetor float chamber into a clean container by loosening the drain bolt; this will help prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

Specified amount:

1 oz of stabilizer for each gallon of fuel (7.5 cc of stabilizer for each liter of fuel)

NOTE:

Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs to be drained instead.

Engine preparation

1. With the key removed and the spark plug lead disconnected, turn the clutch by hand until compression is felt. This puts the valves in the closed position.

2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil.

3. Lubricate all control cables.

9-1

Chassis preparation

1. Block up the frame to raise all wheels off the ground.

2. Clean exterior of the utility vehicle and apply a rust inhibitor.

3. Cover the utility vehicle with a breathable cover and store it in a dry, well-ventilated area.

Battery preparation

1. Remove the battery from the utility vehicle and store it in a cool, dry place that stays between 0 °C (32 °F) and 30 °C (90 °F).

2. Have the battery recharged every 60–90 days to keep it fully charged. The battery must be kept fully charged to avoid damage.

NOTE:

Batteries like the one supplied with your vehicle normally do not require you to check the water level inside the battery for the one year warranty period provided by the manufacturer.

9-2

SPECIFICATIONS

Model YXP700/YXP1000

Dimensions:

Overall length 2492 mm (98.1 in) (YXP700)

3011 mm (118.5 in) (YXP1000)

Overall width 1232 mm (48.5 in) (YXP700)

1289 mm (50.7 in) (YXP1000)

Overall height (steering height) 1275 mm (50.2 in) (YXP700)

1353 mm (53.3 in) (YXP1000)

Height of floor 391 mm (15.4 in) (YXP700)

463 mm (18.2 in) (YXP1000)

Wheelbase 1637 mm (64.4 in) (YXP700)

1939 mm (76.3 in) (YXP1000)

Tread:

Front 940 mm (37.0 in) (YXP700)

1029 mm (40.5 in) (YXP1000)

Rear 980 mm (38.6 in) (YXP700)

1029 mm (40.5 in) (YXP1000)

Ground clearance 116 mm (4.6 in) (YXP700)

143 mm (5.6 in) (YXP1000)

10-1

Model YXP700/YXP1000

Weight:

Dry weight (without battery) 339 kg (747 lb) (YXP700)

452 kg (996 lb) (YXP1000)

Performance:

Maximum speed 24 km/h (15 mph) Minimum turning radius 3.0 m (118.1 in) (YXP700)

4.3 m (169.3 in) (YXP1000)

Seating capacity 2 persons

Engine:

Engine type Air-cooled 4-stroke, OHV Cylinder arrangement Forward-inclined single cylinder Displacement 357 cm

Bore x stroke 85 x 63 mm (3.30 x 2.48 in) Compression ratio 8.0:1 Starting system Electric starter Ignition system TCI Magneto Spark plug type/manufacturer BPR2ES/NGK Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Lubrication system Splash

10-2

Model YXP700/YXP1000

Engine oil:

Type YAMALUBE 4 (10W30) or SAE 10W30

Recommended engine oil classification API Service SE type or higher

Quantity:

Oil change 0.9 L (0.79 Imp qt, 0.95 US qt)

Transmission:

Type V-belt automatic centrifugal V-belt width and outer line length 31 x 1010 mm (1.22 x 39.76 in) V-belt wear limit 27.9 mm (1.10 in)

Transmission oil:

Type SAE 90 gear oil Quantity 0.42 L (0.37 Imp qt, 0.44 US qt)

Steering system:

Type Rack and pinion (YXP700)

Worm and pin (YXP1000)

10-3

Model YXP700/YXP1000

Brakes:

Brake system Mechanical drum brake on rear wheels with self-

adjusters (YXP700) Mechanical drum brake on front and rear wheels with

self-adjusters (YXP1000)

Type of brake Dual internal expanding shoe

Leading/trailing shoes (self-adjusting)

Brake pedal freeplay linkage adjustment 20–25 mm (0.79–0.98 in)

Parking brake:

Type Foot type; with automatic release

Wheel:

Tire size:

Front 20 x 10–8 / 4 PLY (YXP700)

22 x 11–10 / 6 PLY (YXP1000)

Rear 20 x 10–8 / 4 PLY (YXP700)

22 x 11–10 / 6 PLY (YXP1000)

Tire pressure:

Front 70–84 kPa (0.70–0.84 kgf/cm

, 10–12 psi)

Rear 70–84 kPa (0.70–0.84 kgf/cm2, 10–12 psi)

Battery: BCI group 24 (52 AH, 20 hr rate)

RC: minimum 75 min CCA: minimum 400A

10-4

Model YXP700/YXP1000

Bulb voltage, wattage × quantity:

Headlight 12 V, 30 W / 30 W × 2 Taillight Sealed beam × 2

Indicator light:

Engine oil level warning light 12 V, 3.4 W × 1

Specified fuses:

Main fuse 20 A Headlight/signaling system fuse 10 A Auxiliary DC jack fuse 10 A

10-5

MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE

INTERVAL

month km (mi) hours

1 160 (100) 20

6 1,000 (600) 125

12 2,000 (1,200) 250

18 3,000 (1,800) 375

24 4,000 (2,400) 500

30 5,000 (3,000) 625

36 6,000 (3,600) 750

42 7,000 (4,200) 875

48 8,000 (4,800) 1,000

54 9,000 (5,400) 1,125

60 10,000 (6,000) 1,250

DATE OF

SERVICE

MILEAGE

SERVICING DEALER

NAME AND ADDRESS

11-1

REMARKS

YAMAHA MOTOR CORPORATION, U.S.A.

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha Side × Side vehicles purchased from an authorized Yamaha Side × Side Vehicle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.

THE PERIOD OF WARRANTY for YXR OR YXP Yamaha Side × Side vehicles shall be six (6) months from the date of purchase, with no mileage limitation.

MODELS EXCLUDED FROM WARRANTY include those used for non-Yamaha-authorized renting, leasing, or other commercial purposes.

DURING THE PERIOD OF WARRANTY any authorized Yamaha Side × Side Vehicle dealer will free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of Yamaha Motor Corporation, U.S.A.

VEHICLE LIMITED WARRANTY

GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a.

Competition or racing use.

Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts.

Abnormal strain, neglect, or abuse.

Lack of proper maintenance.

Accident or collision damage.

Modification to original parts.

Damage due to improper transportation.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance; such as spark plugs, oil, oil filter, air filter, and brake shoes.

THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:

Operate and maintain the Side-by-Side vehicle as

1. specified in the appropriate Owner’s Manual, and Give notice to an authorized Yamaha Side × Side

2. Vehicle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business.

WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), it is imperative that the Side-by-Side vehicle be inspected and registered for warranty by an authorized Yamaha Side-by-Side Vehicle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer of ownership to the subsequent purchaser. A reasonable dealer imposed fee may be charged for this inspection.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.