Yamaha PRO HAULER 700 Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YXP700

YXP1000

LIT-11626-17-54

JW4-F8199-10

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

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

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR

SAFETY IS INVOLVED!

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

NOTE: 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.

AFFIX DEALER

LABEL HERE

YXP700/YXP1000

OWNER’S MANUAL

©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
	1	LOCATION OF THE WARNING
		AND SPECIFICATION LABELS	1-1
	2	DESCRIPTION AND VEHICLE
		IDENTIFICATION	2-1
		Features ..........................................	2-1
		Utility vehicle serial number.............	2-2
		Key identification number................	2-2
	3	SAFETY INFORMATION..................	3-1
	4	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

	5	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
	6	OPERATION .....................................	6-1
		Starting a cold engine	6-1
		Starting a warm engine....................	6-3
		Stopping...........................................	6-3
		Accessories and loading..................	6-4

	7	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
	8	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

	9	CLEANING AND STORAGE	............ 9-1
		Draining the fuel	9-1
		Engine preparation ..........................	9-1
		Chassis preparation ........................	9-2
		Battery preparation..........................	9-2
	10	SPECIFICATIONS ..........................	10-1
	11	MAINTENANCE RECORD.............	11-1

	12	YAMAHA MOTOR
		CORPORATION, U.S.A.
		VEHICLE LIMITED
		WARRANTY ..................................	12-1
	13	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

9

0

1-2

YXP700

1

OFF		I m p r o p e r u s e c a n r e s u l t i n S E V E R E I N J U R Y o r D E AT H
		• V e h i c l e c a p a c i t y : 1 o p e r a t o r a n d 1 p a s s e n g e r .
ON		• R e m a i n s e a t e d a n d h o l d o n w h i l e i n m o t i o n .
		• T h i s v e h i c l e i s r e c o m m e n d e d o n l y f o r o p e r a t o r s 1 6 a n d o l d e r
		w i t h a v a l i d m o t o r v e h i c l e l i c e n s e . A d u l t s m u s t s u p e r v i s e u s e
		b y m i n o r s . C h e c k s t a t e l a w s f o r m i n i m u m a g e r e q u i r e m e n t s .
		• D r i v e s l o w l y i n t u r n s .
ON		• D r i v e s t r a i g h t u p a n d d o w n h i l l s - d r i v i n g a c r o s s t h e s i d e o f a
		• K e e p e n t i r e b o d y i n s i d e v e h i c l e .
		h i l l i n c r e a s e s t h e r i s k o f o v e r t u r n .
		• P a s s e n g e r a n d c a r g o c a n a f f e c t v e h i c l e h a n d l i n g .
OIL		• V e h i c l e r a t e d c a p a c i t y ( d r i v e r , p a s s e n g e r , c a r g o , t r a i l e r , a n d
		l o a d ) 7 0 0 l b . ( 3 1 8 k g ) o n l e v e l s u r f a c e .
WARNING		LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
		ATTENTION
		T h i s v e h i c l e w a s n o t m a n u f a c t u r e d f o r u s e o n p u b l i c s t r e e t s a n d d o e s
		n o t c o m p l y w i t h f e d e r a l m o t o r v e h i c l e s a f e t y s t a n d a r d s a p p l i c a b l e t o
YAMAHA	JU7-K7761-00	p a s s e n g e r c a r s .

3

•Gasoline is extremely flammable.

•Keep heat, spar ks and open flame away from fuel tank and fuel lines.

•Do not add fuel while engine is r unning or hot .

•Do not modify fuel system . Ser vice should be perfor med by dealer or qualified personnel .

•L’essence est

exstr êmement inflammable.

•Garder étincelles, flammes et chaleur loin du

r éser voir 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 syst ème d ’alimentation . Toute

r évision doit être faite chez le four nisseur ou par du personnel qualifi é.

4

WARNING

AVERTISSEMENT

D o n o t t e m p e r w i t h g o v e r n o r t o i n c r e a s e

s p e e d . O p e r a t i o n a t h i g h e r s p e e d s c a n c a u s e l o s s

o f c o n t r o l t h a t c a n r e s u l t i n

s e v e r e i n j u r y o r d e a t h .

YAMAHA

N e p a s t o u c h e r a u r é g u l a t e u r a f i n

d ’ a u g m e n t e r l a v i t e s s e . U n

f o n c t i o n n e m e n t à d e s v i t e s s e s s u p é r i e u r e s a u r é g l a g e i n i t i a l

p e u t c a u s e r u n e p e r t e d e c o n t r ô l e q u i p e u t m e n e r

à u n e b l e s s u r e g r a v e , v o i r e

f a t a l e .

JN3-K8299-10

USE REGULAR UNLEADED GASOLINE ONLY

Motor Oil

Requirements:

•Use only SAE 10W-30, API service SE or SF.

•Maintain oil level between dipstick “MIN”

and “MAX” marks.

YAMAHA

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.

JN3-K8297-10

2

	WARNING
	Keep hands, body, other
	persons away when closing bed.
	Do not operate the vehicle
	with bed up.
YAMAHA	5UG-K7764-00

5

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.

YAMAHA

JU7-F1696-00

1-3

6

WARNING

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

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

9

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		INTERMEDIATE			EXTENDED
	CHECK OWNERS MANUAL FOR FURTHER DETAILS
THIS	LABEL TO BE	REMOVED BY THE ULTIMATE	PURCHASER ONLY

1-4

YXP1000

7

8

1-5

YXP1000

1

OFF		I m p r o p e r u s e c a n r e s u l t i n S E V E R E I N J U R Y o r D E AT H
		• V e h i c l e c a p a c i t y : 1 o p e r a t o r a n d 1 p a s s e n g e r .
ON		• R e m a i n s e a t e d a n d h o l d o n w h i l e i n m o t i o n .
		• T h i s v e h i c l e i s r e c o m m e n d e d o n l y f o r o p e r a t o r s 1 6 a n d o l d e r
		w i t h a v a l i d m o t o r v e h i c l e l i c e n s e . A d u l t s m u s t s u p e r v i s e u s e
		b y m i n o r s . C h e c k s t a t e l a w s f o r m i n i m u m a g e r e q u i r e m e n t s .
		• D r i v e s l o w l y i n t u r n s .
ON		• D r i v e s t r a i g h t u p a n d d o w n h i l l s - d r i v i n g a c r o s s t h e s i d e o f a
		• K e e p e n t i r e b o d y i n s i d e v e h i c l e .
		h i l l i n c r e a s e s t h e r i s k o f o v e r t u r n .
		• P a s s e n g e r a n d c a r g o c a n a f f e c t v e h i c l e h a n d l i n g .
OIL		• V e h i c l e r a t e d c a p a c i t y ( d r i v e r , p a s s e n g e r , c a r g o , t r a i l e r , a n d
		l o a d ) 1 0 0 0 l b . ( 4 5 4 k g ) o n l e v e l s u r f a c e .
WARNING		LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
		ATTENTION
		T h i s v e h i c l e w a s n o t m a n u f a c t u r e d f o r u s e o n p u b l i c s t r e e t s a n d d o e s
		n o t c o m p l y w i t h f e d e r a l m o t o r v e h i c l e s a f e t y s t a n d a r d s a p p l i c a b l e t o
YAMAHA	JU9-K7761-00	p a s s e n g e r c a r s .

2

WARNING

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

JU9-K7766-01

3

	WARNING
	Keep hands, body, other
	persons away when closing bed.
	Do not operate the vehicle
	with bed up.
YAMAHA	5UG-K7764-00

4

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.

YAMAHA

JU9-F1696-00

5

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

1-6

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		INTERMEDIATE			EXTENDED
	CHECK OWNERS MANUAL FOR FURTHER DETAILS
THIS	LABEL TO BE	REMOVED BY THE ULTIMATE	PURCHASER ONLY

1-7

DESCRIPTION AND VEHICLE IDENTIFICATION

2

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 3 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	Fuel tank cap
This warning light comes on when the engine	Remove the fuel tank cap by turning it coun-
oil level is low. If the light comes on, stop	terclockwise.
the engine, check the engine oil level, and
add oil as necessary. (See page 8-9–8-10).

4

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
	F	FORWARD
	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

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

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

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

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.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

1. Auxiliary DC jack cap

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