Yamaha PRO HAULER 1000, PRO HAULER 700 User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YXP700
YXP1000
JW4-F8199-10LIT-11626-17-54
1-
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.
1-
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
©2003 by Yamaha Motor Corporation,
U.S.A.
1st edition, December 2003
All rights reserved. Any reprinting or
unauthorized use without the written
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
1
AND SPECIFICATION LABELS....... 1-1
DESCRIPTION AND VEHICLE
2
IDENTIFICATION ............................. 2-1
Features .......................................... 2-1
Utility vehicle serial number............. 2-2
Key identification number................ 2-2
SAFETY INFORMATION.................. 3-1
3
CONTROL FUNCTIONS .................. 4-1
4
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
5
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
6
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
7
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
8
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
9
Draining the fuel ..............................9-1
Engine preparation .......................... 9-1
Chassis preparation ........................ 9-2
Battery preparation.......................... 9-2
SPECIFICATIONS ..........................10-1
10
MAINTENANCE RECORD............. 11-1
11
YAMAHA MOTOR
12
CORPORATION, U.S.A.
VEHICLE LIMITED
WARRANTY .................................. 12-1
YAMAHA EXTENDED SERVICE
13
(Y.E.S.) ........................................... 13-1
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
9
1
2
3
4
5
6
7
8
9
10
11
12
1-2
0
13
14
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.
1
OFF
3
• 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.
4
ON
ON
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
2
WARNING
Keep hands, body, other
persons away when closing bed.
Do not operate the vehicle
YAMAHA 5UG-K7764-00
5
with bed up.
6
9
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
7
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
8
0
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
7
8
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.
1
OFF
ON
2
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
3
YAMAHA 5UG-K7764-00
WARNING
Keep hands, body, other
persons away when closing bed.
Do not operate the vehicle
with bed up.
ON
WARNING
4
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
5
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
6
7
8
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
1-
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
1
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
2
3
4
5
6
7
8
9
10
11
12
13
14
●
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
2
3
4
5
6
7
8
9
10
1. Oil level warning light
CAUTION:
Always make sure there is enough engine
oil before starting the engine.
11
12
13
14
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
1
The accelerator pedal controls the utility vehicle’s speed.
Action Vehicle speed
Depress pedal Increase
Release pedal Decrease
1
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
1
Press the parking brake pedal down whenever parking the utility vehicle.
1
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
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