2016 yxz1000r-service-guide-final-ver-2

For Dealer Service and Sales Department use

Shown with optional Genuine Yamaha Parts and Accessories

Model : 2016 YXZ1000R

TABLE OF CONTENTSModel Code and Color Chart 1Specifications 2Feature Map Chassis 3Feature Map Engine 6Feature Map Electrical 7Vehicle Dimensions 8Cylinder Head, Cylinder Numbering and Firing Order 9Valve 11Camshaft 12Cam Chain Tensioner, Service, Operation & TDC Marks 13Air Induction System 22Cylinder 23Piston and Connecting Rod 24Crankshaft and Balancer Weight 26Engine Pump, Oil Flow and Oil Pressure Switch 28Fly Wheel and Prop Shaft 31Clutch and Clutch Hydraulic System 33Transmission 36Shifter Change 38Transmission Lubrication 39Oil Tank and Engine Oil Maintenance Interval 42Cooling System 46Radiator and Water Pump 47Intake 50Air Cleaner 51Throttle Body 55Injector 56Exhaust 57Frame 58Under Frame Protection 59Front Fender and Rear Fender 61Front Grill Carry Bar 63Door and Door Latch Hinge 64Drive Shaft 66Torque Limiter 67Front Differential 68Rear Gearcase 69CVJ Assemblies 70Gear Select and Adjustment 71

74767779818284858687888991939496100102104105107110111112113115116117118119122124126

Reverse Lock-OutSteeringEPS ECU and Diagnostic WireSteering Wheel AdjusterFuel Tank and PumpCab Layout and Driver Foot PedalsOverhead Protection SystemSeatDriver’s Seat AdjusterPassenger HandholdDashboard LayoutFront A-ArmsRear A-ArmsAnti-Sway BarsFront ShocksRear ShocksSuspension Setting ChartBrakesKnuckles and Knuckle BearingsTires and Tire Pressure ChartWheelsCargo BedSun TopMeter AssemblyHeadlights and TaillightAC Magneto Generator Assembly, Max Output Ignition CoilsRectifier Regulator AssemblySeat Belt and Parking Brake BuzzerCenter Console, Fuses and Relay Information ECU Pin-out MapsYamaha Diagnostic Tool Information Genuine Yamaha Accessories

MODEL MODEL CODE COLOR NAME COLOR CODE

YXZ1000REPS SE YXZ10YPSGY 2HC1

Body: Yamaha Yellow (painted)Rear fenders: Yamaha Yellow (painted)Hood: White (PP*)

Body: Yellow Metallic (painted)Hood: Bluish White Solid 1 (BWS1)

YXZ1000REPS

YXZ10YPXGL 2HC4Body: White (PP*)Rear fenders: Racing Blue (PP*)Hood: Racing Blue (PP*)

Body: Bluish White Solid 1 (BWS1)Rear fenders and Hood: Deep Purplish BlueSolid E (DPBSE)

YXZ10YPXGO 2HC4Body: Blaze Orange (PP*)Rear fenders: Blaze Orange (PP*)Hood: Gray (PP*)

Body & rear Fenders: Vivid Yellowish Red Solid 4 (VYRS4)Hood: Dark Gray Metallic E (DNME)

Model : 2016 YXZ1000R

*These parts are polypropylene plastic molded in the color indicated.

YXZ10YPSXG

Y, L , O

1ST - 3RD characters = Product group4th & 5th = engine class, 10 = 1000cc 6th = Y signifies YXZ or YFZ sport models 7th = EPS & 4WD 8th = S signifies Special Edition model8th = X signifies a standard model9th = G indicates 2016 model yearLast character = color code, Y = Yellow, L = Blue, O = Orange

1

Model : YXZ1000RCATEGORY

Engine• Type:• Bore x Stroke:• Compression Ratio:• Throttle Body:• Fuel Requirement• Ignition:• Starting System:• Transmission:• Drive Type:• 4WD System:Chassis• Suspension / Front• Suspension / Rear:• Brakes / Front:• Brakes / Rear:• Tires / Front:• Tires / Rear:• BatteryMeasurements• L x W x H:• Wet weight:• Wheelbase:• Min. Turning Radius:• Ground Clearance:• Fuel Capacity:• Instrumentation:

• Lighting:

SPECIFICATIONS

998cc, 4-cycle, 3-cylinder, liquid-cooled, DOHC80mm x 66.2mm11.3 : 13, Mikuni® 41mmRegular gas; 86 PON ([R+M]/2) or higher, 91 RON or higher / ethanol content not to exceed 10%TCI ElectricConstant mesh, sliding gear - 5 Speed Non-unit construction (transmission separate from engine assy.) w/ wet multi-disc clutch, shaft with flywheelYamaha On-Command® 3-way locking differential system: 2WD, 4WD and 4WD with Diff-lock

Independent double wishbone with anti-sway bar, 16.2-in travel, FOX 2.5 Podium® RC2 Shocks®

Independent double wishbone with anti-sway bar, 17.0-in travel, FOX 2.5 Podium® RC2 Shocks®

Dual hydraulic discsDual hydraulic discs / shaft mounted, disc parking brake MAXXIS® Bighorn™ MU09 / 27 x 9.00R-14, cast aluminum wheelsMAXXIS® Bighorn™ MU10 / 27 x 11.00R-14, cast aluminum wheelsFactory-filled GS U1-H11L, 12 V, 28 AH (10 H)

122.9 in (3121mm) x 64 in (1626mm) x 72.2 in (1834mm)1510 lb90.6 in (2300mm)236 in (6000mm) minimum turning radius12.9 in (330mm)8.98 US gal (34 L)Analog Tachometer, Digital Speedometer w/ Shift Indicator, LCD Display w/ Odometer, Dual Trip Meters, Battery Voltage, Hour Meter, Fuel Meter, Clock, Water Temp, Gear Position Indicator, 4WD/Diff-Lock Status, EPS and Engine Trouble LightFour 12v12.4/6.2W LED multi-reflector headlights, 12v2.3/0.2W LED taillight w/ brake light

2

FEATURE MAPModel: 2016 YXZ1000R

27 inch front & rear tireSTD: aluminum cast wheels

SE: bead lock wheels

4-beam LED headlights

Color matched rigid bushing pivot double A-arm suspension w/

piggyback shocks

Sun top

Color matched rigid bushing pivotdouble A-arm suspension

piggyback shocks

New Development ItemCurrent Technology

Front rear brake system245mm disc brake &

2 piston caliper

Roof support

All new appearance exterior and interior partsSE: painted body, STD: 2 color options

full length TPO plastic skid plates

Cut and sew high back seats

Slide adjusting driver seat (no tool)

3


5-speed sequential manual transmission +

reverse w/hydraulic clutch

Electric Power Steering

2WD/4WD Diff-lock


Tilt adjusting, soft-grip steering wheel

9 gal fuel tank

All new appearance exterior and interior partsSE: painted body, STD: 2 color options

full length TPO plastic skid plates

High–capacity cooling system

Analog tachometer, digital speedometer

& shift position indicator

4


4-cycle 3-cylinderDOHC 998cc engine


Dry sump external oil tank

LED tail light

Maximum 300 lb capacity - plastic cargo bed

Return to TOC

5


Displacement 998ccBore x Stroke 80mm x 66.2 mmCompression Ratio 11.3 : 1Number of cylinders 3Cooling System Liquid CooledLubrication Dry SumpValve Train DOHC

Transmission Manual transmission/5-speed with reverse

Engine weight 117 lb (53 kg)Transmission weight 87 lb (39.5 kg)

New front differential

5-speedtransmission

w/ reverse

Torque limiter Cam damper

(middle drive shaft)

Cam damper (input shaft)

Flywheel

Prop shaft

AI system

Dual stage air cleaner element

New 998cc dry sump 3 cylinder engine Cylinder #1 is the forward

cylinder, #3 is the rear cylinder

Piston (80mm) / 66.2mm stroke

crankshaft

High capacity exhaust system (catalyst in

muffler)

External parking brake

New gearcase

Return to TOC

6


LED Tail light

Ignition coils

Center console battery / fuses / relays

Multi-function display

Seat belt / parking brake buzzer

Ignition switch

Headlight / Diff-lock / switches

EPS ECU

Rectifier / regulator

LED “4-beam” headlights

AC magneto assembly

Starter motor

Oil pressure switch

Neutral switch

Gear position switch

Speed sensor

Return to TOC

7

DIMENSION MAP Model: 2016 YXZ1000R

A Overall length 122.9 in 3121mm

B Overall width 64 in 1626mm

C Overall height 72.2 in 1834mm

D Wheel base 90.6 in 2300mm

E Ground clearance 13 in 330mm

F Tread (front) 55 in 1397mm

G Tread (rear) 53 in 1346mm

H Maximum Water Depth 15.4 in 390mm

C

FA

DE

G

H

B

Return to TOC

8

Component:

At-a-Glance

Service Tip In-depth Info

Model: 2016 YXZ1000R

Cylinder Head

• 3 cylinder DOHC 4 valve cylinder head• Compression ratio: 11.3:1

IN: 14 degreesEX: 14 degreesAluminum head cover

Anti-vibration boltCombustion chamber volume

= 24.88cc

• Anti-vibration bolt reduces engine noise

Engine oil filler cap

Return to TOC

9

SERVICE TIPModel: 2016 YXZ1000R

Cylinder Numbering and Firing Order

Return to TOC

10

Component:

At-a-Glance



Valve

• Steel intake and exhaust valves are used – 8GL-type• Shim under bucket design• 7.5mm adjusting pad is used – 1HX-type

88.82mm

87.92mm

31mm

26mm

IN

EX

Diameter = 4.5mm

Diameter = 4.5mm

4C8 Lifter

1HX Adjusting Pad

• Valve Clearanceintake – 0.15~0.22mmexhaust – 0.21~0.25mm

• Steel intake and exhaust valves and shim under bucketdesign deliver proven Yamaha reliability while providingthe best performance

Return to TOC

11

Component:

At-a-Glance



Camshaft

• New design camshafts are used

Valve lift heightIN EX

8.6mm 9.9mm

Intake

Exhaust

Locating boss

Locating boss

Larger identification rib

Smaller identification rib

IntakeExhaust

Align 2HC mark with large hole on camshaft flange,also note the I and E stamping locations when the

gears are properly installed

• The camshaft sprockets are the same part number• Use the installation information shown above if disassembly or part replacement is required

Secondary cam identification marks, Exhaust cam has two dots, Intake cam has one

Return to TOC

12

Component:

At-a-Glance



Timing Chain Tensioner

• All new design, self-adjusting hydraulic timing chain tensioner• This tensioner uses oil pressure from the engine as well as a coil spring to

control timing chain tension

Tensioner

Chain guide

Chain guide

“UP” arrowRod

Timing chain

• Procedure for retracting and releasing the timing chain tensioner is different from previoustypes

• Refer to the following pages for service information

Return to TOC

13


Timing Chain Tensioner Inspection & Tensioner Rod Retraction

Disassemble, Clean and Inspect Timing Chain Tensioner• Squeeze the timing chain tensioner clip (3), then remove the timing chain

tensioner rod (1), spring (2) and spring guide (5)

• Clean and check all parts for damage or wear, replace as needed

• Remove any motor oil remaining in the tensioner housing

The timing chain tensioner spring is compressed and may cause the rod to extend out of the housing and fall loose when you squeeze the clip.

ReassemblyStep 1• Reposition circlip (a) from the end of the timing chain tensioner rod into the

groove (b) as shown

Step 2• Install the clip (1) into the internal groove in the tensioner housing, marked

with the arrows (2) as shown

(5)

Return to TOC

14


Step 3• Squeeze clip (1) and install spring (2) with plastic spring guide (5), tensioner rod (3)

into the tensioner housing (4)

Be careful as you install the tensioner rod and begin to compress the timing chain tensioner spring, the tensioner rod may spring back quickly and fall loose until it is held in the housing by the clip.

TIPUse a small hobby or machinist's vice (5) to slowly compress the timing chain tensioner rod (3) into the tensioner housing (4) while squeezing the timing chain tensioner clip (1) – the clip should always be free to move in the housing as you tighten the vice.

Step 4• Continue to squeeze clip (1) so it passes over each groove in the tensioner

rod as the rod is pushed further into the tensioner housing

• Finally position clip (1) into groove (c) on the tensioner rod when groove (c)comes near the arrow marks

Timing Chain Tensioner Inspection & Tensioner Rod Retraction (Continued)

Tighten the vice very slowly while keeping the clip (1) squeezed. If you will feel the vice become tight and the tensioner rod does not want to compress easily, the clip is out of place and has become wedged in the housing. If this occurs, loosen the vice, adjust the clip position, and resume tightening the vice.

(5)

Return to TOC

15


Step 5

• Continue to squeeze clip (1) as you compress the tensioner rod (3) further intothe tensioner housing (4) very slowly

• As the tensioner rod (3) is pushed further into the housing, circlip (a) will bemoved into position (e) on the tensioner rod which will lock the rod in place inthe tensioner housing (4)

• Make sure clip (1) is in the groove (c), as outlined in Step 4., and that it isaligned with the arrows (d) and release the clip

• Slowly release the pressure on the vice and make sure the tensioner rod (3)stays locked in the retracted position

NOTE• Refer to the following page for timing chain tensioner installation and release

procedures

• When the tensioner assembly is installed in the engine, the tensioner rod willbe pushed back into the housing slightly by the timing chain guide, which willforce the circlip (a) out of groove (e) onto the end of the rod which will unlockthe tensioner rod and the spring will then be able to extend the rod outward asneeded during normal operation

Timing Chain Tensioner Inspection & Tensioner Rod Retraction (Continued)

TIPMake sure the tensioner rod (3) is not inserted beyond position (e) as shown in the illustration or the tensioner rod (3) will not be locked by circlip (a).

Repeat steps 1 to 5 if the tensioner rod is inserted too far in and the circlip (a) becomes unlocked.

Return to TOC

16


Camshaft and Tensioner Installation & Release Procedure

TIP• The camshafts are installed in this engine type with cylinder #3 at TDC on valve

overlap, not TDC on the compression stroke (this allows the camshafts to be installedwith a very small amount of pressure from the valve springs)

• Valve overlap is 360 degrees after TDC compression• The Intake (2) and Exhaust (1) camshafts can be determined by the size of the

identification rib (circled in the illustration)

Step 1• Support the timing chain and turn the crankshaft clockwise to align the TDC mark (a)

on the AC magneto rotor with the stationary pointer (b) on the magneto cover

• The TDC mark is the single line “I” to the left of the ignition timing “H” mark

Step 3

• When the timing chain is set onto the sprockets in the correct position, use cableties (3) to secure the timing chain to the sprockets

Step 2

• Pull the timing chain tight on the intake side, and set the timing chain onto the Intakecamshaft sprocket (1) so that the #3 cylinder intake cam lobes (c) are in the positionshown and the sprocket alignment marks (b) are parallel with the cylinder head covergasket surface

• Pull the timing chain tight towards the exhaust side and set onto the Exhaust camsprocket (2) and place the camshaft into the cylinder head so that the #3 cylinderexhaust cam lobes (c) are in the position shown and the sprocket alignment marks(b) are parallel with the cylinder head cover gasket surface

TIP• This engine is rotated clockwise from the AC magneto end• Cylinders are numbered front to back as the engine is positioned in the unit (cylinder

#1 is the front cylinder, #3 is the rear cylinder)

Return to TOC

17


Step 4• Make sure all the slack in the timing chain is on the exhaust side

• The exhaust cam (2) will tend to rotate slightly clockwise due the position of the camlobes, you can rotate the cam counterclockwise by hand when the camshaft caps arenot installed to double check the alignment of the timing marks (b) with the cylinderhead cover gasket surface

Step 5• Note the punch marks (b) on the #3 cylinder camshaft lobes and alignment marks (c)

on the cam caps

• These should also align when the camshafts are correctly timed

• The individual camshaft caps can be identified with the “I” for intake and “E” forexhaust marks

Step 6• Install the camshaft caps and temporarily tighten the bolts just enough to bring the

cap down into proper position

• Apply a small amount of engine oil to each camshaft bearing surface• Lubricate the camshaft cap bolts with engine oil• The camshaft cap bolts must be tightened evenly or damage to the cylinder head,

camshaft caps, and camshafts will result• Do not turn the crankshaft when installing the camshafts to avoid damage or

improper valve timing

Camshaft and Tensioner Installation & Release Procedure(Continued)

Return to TOC

18


Step 7• Make sure the timing chain tensioner rod is retracted and locked in place (refer to the

previous section for service information on the timing chain tensioner)

• Install the tensioner (2) with the arrow mark (b) facing up and a new gasket (1) withthe “L” mark (a) as shown

• Torque the bolts to 12 Nm (1.2 m·kgf, 8.7 ft·lb)

TIP• When the timing chain tensioner bolts are tightened, the tensioner rod will contact the

timing chain guide and will be pushed back slightly, this will unlock the tensioner rod• The timing chain tensioner rod and spring should now control the timing chain slack as

normal• It is difficult to hear when the timing chain tensioner is released, there is a very low

click sound when circlip (a) snaps free from the groove (e) on the tensioner rod• There is no visible indication when the tensioner is released, the intake camshaft does

not move and the timing chain will still have slack between the intake and exhaust camsprockets

Step 8• Torque the camshaft cap bolts to proper specification in the order shown

• Camshaft cap bolts: 10 Nm (1.0 m·kgf, 7.2 ft·lb)


Return to TOC

19


Step 9• Remove the cable ties (1)

• It is very important to only rotate the motor clockwise, if the motor is rotatedcounterclockwise with the cylinder head cover removed, even a few degrees, thetiming chain will climb over the camshaft gear teeth and change the camshaft timing(jump time) – this can happen even if the timing chain tensioner is installed

• As the motor is turned by hand there will be positions where the camshafts willquickly rotate a small amount, due to valve spring pressure on the camshaft lobes,resulting in audible clicking noises from the timing chain tensioner since there is nooil pressure, this is normal

Step 10• Rotate the engine clockwise by hand very slowly several times and align the TDC

mark (a) on the AC magneto rotor with the stationary pointer (b) on the magnetocover when cylinder #3 is at TDC on valve overlap (360 degrees after TDCcompression)

• The TDC mark is the single line “I” to the left of the ignition timing “H” mark

• Check that timing marks (d) on the camshaft sprockets are parallel with the cylinderhead cover gasket surface

Step 11• Check that punch marks (c) on the camshafts align with the timing marks (d) on the

camshaft caps

• Install the cylinder head cover following the instructions in the appropriate servicemanual


Return to TOC

20


AC Magneto Rotor Marks

• The single mark (a) to the left of the “H” mark (b) is TDC fornumber 3 cylinder – used for camshaft timing to the crankshaft

• The “H” mark (b) is for dynamic verification of proper ignitiontiming and ignition advance, i.e., using a timing light

• The single mark (c) is used to properly align the balancer shaftcounter-weight to enable removal of the water pump assembly

(c)

(a)

(b)

Return to TOC

21

Component:

At-a-Glance



Air induction system

• Air induction system inlet ports are adopted on the cylinder head• ECU controlled solenoid valve

Solenoid valve

Reed valve

AIS portReed valve

Fresh air intake

• The AI system introduces fresh air into the exhaust portto help complete the combustion process

Return to TOC

22

Component:

At-a-Glance



Cylinder

• New design aluminum cylinder body• Cylinder bore size: 80mm• Ceramic coated cylinders - ceramic powder-dispersed, Ni-P composite

coating

Bore = 80.0mm

• Ceramic powder-dispersed, Ni-P composite coating, thesame process used on Yamaha sport bikes

• This is not the same process as Nikasil®

Return to TOC

23

Component:

At-a-Glance


Model: 2016 YXZ1000RPiston

• New design 80mm bore piston is used• Scraper type 2nd ring is used• Sacrificial “TIN” coating is used for break-in period

Top ring

2nd ring

Sectional view of piston ring

80mm

Directional mark (towards exhaust)

Return to TOC

24

Component:

At-a-Glance


Model: 2016 YXZ1000RConnecting rod

118.5mm

• Rod bolts must not be reused• Tightening method

1st : 20 Nm (2.0 m·kg, 14 ft·lbf)2nd: angle-torque to 115-125 degrees

12 point / 8mm socket needed for rod bolts

• Steel connecting rods are adopted• Connecting rod nuts are eliminated (nut-less design)• Connecting rod utilizes a thermal refining treatment on the small end

Thermal refining treatment

19mm

41mm20mm

Machined surface

Piston pin oiling holes

Top View

• New steel connecting rods, with a nut-less design toreduce overall weight

Return to TOC

25

Component:

At-a-Glance



Crankshaft

• Press-method crankshaft is used• Stroke = 66.2mm

• Press-method manufacturing process is adopted (forgingprocess without twisting of the metal) to provide theneeded strength to the crankshaft assembly

Oil to cam chain tensioner and

camshafts

Oil flows into crankshaft main bearing journals from main oil galley in crankcase

Oil pump drive sprocket

Cam chain drive sprocket

Oil spray to cool AC Magnetothru rotor bolt

Piston cooling jetsCon rod big ends

Return to TOC

26

Component:

At-a-Glance



Balancer Weight

• Newly designed one axis coupling balancer

• 1:1 gear ratio

IntakeIntake

Balancer weight

Balancer weight

• Single-shaft counter-balancer• Helps reduce engine vibration - increasing customer

comfort and engine durability

Return to TOC

27

Component:

At-a-Glance



Engine Oil Pump

• Dry sump oil system• Cartridge oil filter is used – 5GH-type

• Oil capacities:Engine fully disassembled - 3400cc (3.7 US qt)Oil change - 2500cc (2.64 US qt)Oil change with oil filter - 2700cc (2.85 US qt)

• Oil flow is optimized to provide the best lubrication toall components throughout the entire engine

Oil Pump Assembly - integrates 2 pumps • 1 Scavenge pump with 2 pick-ups

• The Oil sump divider separates the crankcase sumpinto 2 chambers

• Scavenge pump pulls oil out of the sump andpumps it into the oil tank

• Oil flows through Oil cooler assy. before going intotank

• 1 Feed pump• Oil flows from the oil tank to the feed pump• Oil is pumped through the oil filter, then into the

engine• See oil flow diagram on following page

Oil sump divider

Oil pick-ups

Scavenge pump

Feed pump

Return to TOC

28


Engine Oil Flow Diagram

• Dry sump oil system• Cartridge oil filter is used – 5GH-type• Oil capacities: YAMALUBE Oil

Engine fully disassembled - 3400cc (3.7 US qt) Oil change - 2500cc (2.64 US qt)Oil change with oil filter - 2700cc (2.85 US qt)

1. Oil pump assembly2. Oil strainer3. Scavenge pump4. Oil cooler5. Feed pump6. Check valve7. Relief valve8. Oil tank9. Oil filter10. Oil pressure switch11. Main gallery12. Crankshaft13. Piston coolers14. AC Magneto rotor bolt15. Timing chain tensioner16. Exhaust camshaft17. Intake camshaft

Return to TOC

29


The new YXZ1000R features an oil pressure switch in the main oil galley.

The oil pressure circuit is monitored by the ECU, and is included in the YDT system.

OPERATION1. When the engine is off (no oil pressure) the oil pressure switch is closed, there is

continuity to ground on the Yellow wire (approx. 2 ohms) – YDT Monitor Mode will show ON.

2. When the oil pressure exceeds approximately 2 psi, the oil pressure switch opens, there is no continuity to ground (infinite resistance) – YDT Monitor Mode will show OFF.

3. The ECU will perform a self-diagnosis of the oil pressure switch circuit, as well as certain FI circuits and other electrical systems, when the Main Switch is first turned on.lf the ECU does NOT detect a complete circuit to ground on the Yellow wire during this self-diagnosis, the Check Engine Light will illuminate and the meter will display Fault Code 85.

Engine Oil Pressure Switch Operation and Troubleshooting

Oil pressure less than 2 psi, switch closedSwitch closed = YDT ON*

Oil pressure more than 2 psi, switch openSwitch open = YDT OFF*

* YDT Monitor Mode line number 21

Return to TOC

30

Component:

At-a-Glance


Model: 2016 YXZ1000RFlywheel

• Flywheel to help reduce engine vibration

• Balancing holes are also used to attach the flywheel holder tool

175mm

FWD

• Flywheel dampens the engine vibration and helpsmaintain momentum in the drive line

Balancing holes 19mm

Flywheel

Return to TOC

31

Component:

At-a-Glance



Engine to Transmission Prop Shaft

Oil Tank Lines

• U-joint shaft is adopted (reduced noise and vibration)• Engine output support carrier with ball bearings• 3-piece prop shaft guard is adopted• Splines are weather-protected by an O-ring

3 Piece prop shaft guard

Prop shaft guard

Prop shaft

FWD

Splined couplers

Flywheel

Support bearings

Bearing located in engine case by pin

U-joint

Steel

SteelPlastic

• The U-joints can be removed without unbolting the engine or transmission• Unbolt the yoke at the engine / flywheel side

Return to TOC

32

Component:

At-a-Glance



Clutch

• New design multi-plate wet clutch• Input shaft cam damper is adopted• Gear Ratio → 88/53 = 1.660

Input from engine

• The new clutch is designed specifically to withstand theengine output and deliver reliable power to thetransmission

• Cam damper reduces shock loads in the drive line

Slave cylinder

Clutch rod

Clutch

Input shaft

Input shaftCam damper

Return to TOC

33

Component:

At-a-Glance



Clutch (continued)

• 11 friction plates• 10 steel plates• 3 separate judder spring/clutch plate assemblies are adopted

• 3 separate judder springs improve the feel duringclutch engagement

• The clutch plates with the judder springs are held in place by a retaining wire• The outside friction plate is offset due to the taper of the outer clutch basket

(reduces noise)

5YU-type friction plates

Primary drive gear

Primary drive gear dampers

2H7-type steel plates

Retaining wire

2H7 steel plate

Judder spring

Judder seat

1PK friction plate

The are 3 separate sets of this judder spring & clutch plate configuration, which are installed first, and held in place by the retaining wire

Tab on the outside plateis offset when

installed

Return to TOC

34

Component:

At-a-Glance



Clutch Hydraulic System

• Foot operated clutch system is adopted• Clutch master cylinder and slave cylinder system is adopted

Clutch master cylinder

Clutch pedal

Clutch slave cylinder

• Use DOT 4 Brake Fluid

Return to TOC

35

Component:

At-a-Glance



Transmission

Output to front differential

Output to rear gearcase

• Oil Capacities:Assembly - 1500 ± 20ccOil change - 1500cc (1.59 US qt)

• Manual 5 speed sequential transmission with reverse is adopted• Dual cam dampers are utilized on both the input and output shafts

Secondary gear & clutch

Main shaft

Counter shaft

Reverse idler shaft Input shaft cam damper

Output shaft cam damper

Return to TOC

36

Component:

At-a-Glance



Locating boss

Sprayer Holes

Transmission (Continued)

• Reverse gear idler shaft must be installed so the “D-shaped” locating boss fits into casecorrectly

• Oil sprayer holes will be correctly positioned when the shaft is properly installed

• Main shaft / countershaft axles utilize ball bearings• Fixed reverse idler gear shaft is adopted with pressurized oil sprayer

holes to lubricate the transmission gears

Reverse idler shaft

Counter shaft

Main Shaft

Middle driven shaft

R1st

2nd

3rd4th5th

Gear Ratio

1st 35/17 = 2.059

2nd 34/22 = 1.545

3rd 31/26 = 1.192

4th 25/26 = 0.962

5th 25/31 = 0.806

reverse 37/15 = 2.467

middle 41/22 = 1.864

Return to TOC

37

Component:

At-a-Glance



Shifter Change

• Shift claw / shift drum / shift fork design is adopted• Segment / detent design is utilized

• The outside shift forks are the same part & number; can be placed in either position

Outside shift forks

Shift drum

Shift shaft

Shift detent

Shift claw

Middle shift fork

Return to TOC

38

Component:

At-a-Glance



Transmission Lubrication

• Externally accessible oil filter screen eases maintenance• Can be removed and cleaned without splitting the transmission cases

• Dedicated trochoid oil pump is adopted• Oil Pump is driven off the input shaft damper• Oil filter screen is adopted

Oil filter screen

Trochoid oil pump

Input shaft damper

Oil pump

Oil filter screen

Return to TOC

39


• The oil fill and oil filter screen can be accessed by removing the passenger seat bottom and passengerside center console cover. The transmission oil drain can be accessed utilizing a cut-out in the centerskid plate (reference page 60)

• The is a wet-clutch design, must use JASO MA certified oil in the transmission to preventpossible clutch slippage from contaminated friction clutch plates

• Refer to the Owner’s or Service Manual for oil change interval

Transmission oil check

Transmission oil drain

Oil filter screen

Remove fastener then pull the oil filter screen outward from transmission case

Fastener

Oil TypeYAMALUBE 10W-40 Oil CapacityAssembly - 1500 ± 20ccOil change - 1500cc (1.59 US qt)

Return to TOC

40


Transmission Oil Flow Diagram

Transmission sump

Oil pick-up

Oil filter screen

Oil pump

Input shaft damper axle

Main shaft axle

Countershaft axle

Reverse idler gear shaft

Clutch

Return to TOC

41

Component:

At-a-Glance



Oil Tank

• High efficiency, low maintenance oil cooling system

Oil tank lines

FWD

• External dry sump oil tank is adopted• Catch bottle is utilized

• When overhauling the engine, pour;1700cc of oil in the motor, then pour 1700cc in the oil tank

• 1700cc + 1700cc = 3400cc total• * For maximum engine protection, the oil filter should be replaced at each oil change

interval

Oil tank drain

Total Oil Capacity 3400cc

With oil filter replacement 2700cc

Without oil filter replacement* 2500cc

YAMALUBE Oilis recommended,

see next page for weight/type

Checking Oil Level1. Start engine and warm oil to

140º F (60º C)2. Let engine idle for at least 10

seconds3. Unscrew oil tank dipstick wipe off

and reinsert into oil tank (DONOT screw dipstick into tank)

4. Check oil level on dipstick

Oil tank

Dipstick

Return to TOC

42


Engine and Driveline Lubrication Charts

Return to TOC

43

Component:

At-a-Glance



Oil Tank (Continued)

• Oil tank has internal baffling• Oil is cooled by the engine coolant via a heat-exchanger type oil cooler

Oil tank bafflingCatch bottle

Heat-exchanger type oil cooler

Dipstick

• The internal baffling of the oil tank helps prevent oilstarvation for conditions encountered in an off roadenvironment

Return to TOC

44


To access the oil tank dip stick the cargo bed cover must be removed

Remove the 5 cargo bed ¼ turn quick fasteners then remove the cover

¼ Turn Quick Fasteners

Oil tank dip stick

Return to TOC

45

Component:

At-a-Glance



Cooling System

• New radiator and fan assembly is adopted• Thermostat utilized – 5LP-type• Thermo sensor is utilized – 5YP-type

• High efficiency, low maintenance, thermostat controlledcooling system with automatic recovery system

• Engine ECU controls the fan activation, based onengine coolant temperature

• With circuit breaker protection

Total coolant capacity 3750cc

Total coolant recovery tank 250-310cc

50/50 distilled water and anti-freeze mix

Radiator and fan assy.

5LP Thermostat

Coolant hoses

FWD

Thermostat Assembly

5LP Thermostat

5YP Thermosensor

Recovery tank

Coolant drain

Return to TOC

46

Component:

At-a-Glance



Radiator

• New design aluminum radiator/fan assembly• Manufactured by T.RAD® North America, Inc.

394.2mm

400mm

28mm

• Radiator fill is located underneath the center hood access• Radiator capacity: 47.4kw

Return to TOC

47

Component:

At-a-Glance



Water Pump

• New design Mikuni® water pump• Water pump is driven off the balancer shaft• Mechanical seal with integrated weep hole

• Working RPM - 6700rpm• Working pressure – 21.7 psi (150kPa)• Water delivery - 47.5 gal/min (180 L/min)

Water pump

5LP-type Thermostat

Balancer shaft

Weep hole drain tube

Water pump

ImpellerMechanical seal

Bearing

Drive gear

• The water pump is driven off the balancer shaftresulting in less moving parts which translates to betterreliability

Return to TOC

48


Water Pump Removal

• Rotate the engine until the single mark* (a) on AC magneto rotor aligns with the stationary pointer (b) on the crankcase cover• This will allow the water pump driven gear to clear the balancer shaft weight as the pump is removed

* Be sure to align the single mark “I”, not the TDC mark “I” to the left of the ignition timing “H” mark

Return to TOC

49

Component:

At-a-Glance



Intake

• High mounted intake• Intake for the air box is located inside the center console

• High volume for increased power output throughoutthe entire range, easy to maintain intake system

• Foam filter element MUST be serviced with YAMALUBE Foam Filter Oilbefore delivery

• Air filter element should be checked more often in dusty / wet conditions

FWD

Side View

Top View

Return to TOC

50

Component:

At-a-Glance



Air Cleaner

• New design air filter case• Easy access layout for primary element

Secondary air cleaner elementPrimary air cleaner element

Primary Air Cleaner• Clean and replace if necessary every 200-400 mi (300-600 km)Secondary Air Cleaner• Replace every 1200-3000 mi (2000-5000 km)NOTE: Service both the Primary and Secondary air cleaners more often in wet or dusty conditions.

Wet paper type (viscous)

Oiled urethane foam

Center torque cam type

(tool-less)

• Dual air filters elements provide optimal filtration of airto the engine providing the best possible power whilestill maintaining an easy access to primary air cleanerelement

Return to TOCReturn to TOC

Return to TOC

51

Component:

At-a-Glance


Model: 2016 YXZ1000R• Easy access to primary foam air cleaner element under cargo bed cover• Tools are not required to service primary foam air cleaner element• Viscous paper air cleaner can be accessed from the right rear wheel well

• Continued on following pages

Air temp sensor

Air box drain tube

Viscous paper air filter Foam air filter

Air Cleaner (continued)

Return to TOC

52


To remove the foam air filter element the cargo bed cover must be removed Remove the 5 cargo bed ¼ turn quick

fasteners then remove the cover

Remove the foam air cleaner element by rotating the air cleaner case cap counter clockwise

¼ turn quick fasteners

Return to TOC

53


To remove the paper air filter element remove the oil tank cover and oil catch bottle and remove the air box cover fasteners

Remove the 11 air box lid fasteners then remove the cover

Remove the 3 oil tank cover fasteners then

remove the cover

Air box fastener

Return to TOC

54

Component:

At-a-Glance



Throttle Body

• Triple 41mm throttle bodies are utilized• Idle Speed Controller (ISC) stepper motor is adopted• Dual pressure sensors are utilized eliminating the need for a cylinder

identification sensor

• Sensor #2 connected to cylinder #1 only – performs cylinder ID function and providesatmospheric pressure information

• Sensor #1 connected to all cylinders

New injectors

3B4-type throttle position sensor

1WS-type pressure sensors

Throttle stop screw

Fuel inlet

ISC

ISC - fresh air inlet

5VK-type pulsationdamper

Model code marking

2HC1 00

Sensor #2 Sensor #1

Return to TOC

55

Component:

At-a-Glance



Injector

• New Mitsubishi® 4-hole injector is adopted

4-hole Injector

Return to TOC

56

Component:

At-a-Glance



Exhaust

• New, stainless steel construction exhaust system• Honeycomb catalyzer integrated into muffler• Removable spark arrestor

• High volume exhaust system, meeting EPA / CARBregulations

• Catalyst information; 300 cells/in²

Honeycomb 3-way catalyzer (83x76.3mm)

Spark arrestor

Return to TOC

57

Component:

At-a-Glance


Model: 2016 YXZ1000RFrame

• New design frame is utilized• Sub frame section over transmission is adopted• Bolt on engine bracket• New design roll-over protection structure (ROPS)*

• Sub frame is removable to help aid in the removal of the transmission, shifter rigidity and tosupport the center console components

ROPS*

Main frame

Sub frame

• *The ROPS system complies with the AmericanNational Standard for Recreational Off-HighwayVehicles, ANSI/ROHVA-1-2011 Standard

Bolt-on engine bracket

(color matched)

Return to TOC

58

Component:

At-a-Glance



Under Frame Protection

• 3-piece TPO removable middle skid plates• TPO side guards are adopted• Rear Guard TPO is 6mm in thickness• All other guards are 4mm in thickness

• TPO = thermoplastic olefin• TPO is a good material for impact resistance, flexibility

and wear• The vehicle will easily glide over most obstacles

encountered on the trail

FWD

Rear guard

Front guard

Middle guard

Side guard

Side guard

• Full under frame protection with easy access to service items• See next page for details

Return to TOC

59


Engine oil filter drain cutoutRear gearbox oil drain

Front gearbox oil drain

Transmission drain

Oil filter galley drainCoolant drain

Return to TOC

60

Component:

At-a-Glance


Model: 2016 YXZ1000RFront Fender Assy.

• New design front fender• Polypropylene construction (non-painted models)

• Center hood gives easy access to the radiator, recovery tank, master cylinder reservoirs andEPS ECU

Center hood access

Center hood fasteners

Center hood fastener type

Painted SE models use painted TPO in place of PP

• TPO = thermoplastic olefin• PP = polypropylene

Return to TOC

61

Component:

At-a-Glance



Rear Fenders

• New design rear fender• Polypropylene construction (non-painted models)

Right rear fender panel Cargo bed

Left rear fender panel

Painted SE models use painted TPO in place of PP

• TPO = thermoplastic olefin(also known as thermoplastic polyolefin)

• PP = polypropylene

Return to TOC

62

Component:

At-a-Glance



Front Grill and Carry Bar

• New design front grill• New design front carry bar• Complement the “four eyes” LED headlight layout

Front carry bar

Grill

Return to TOC

63

Component:

At-a-Glance



Door

• Blow-molded door panel• Color matched outer cover door panels are utilized

Inside View

Outside View

Top View

Mark is placed here to indicate door handle position from the outside

Return to TOC

64

Component:

At-a-Glance



Door Latch and Hinge

• Smooth durable door latch system with less effort

• 2-stage automotive-style latch is utilized• Door handle mechanism is protected inside the door panel• Coil style door return springs are utilized

Door handle rod

2-stage latch

Return spring

Hinge mounting fasteners

Striker bolted to frame

Return to TOC

65

Component:

At-a-Glance



Drive Shaft

• Single piece front driveshaft with U-joint fittings• Single piece inline rear driveshaft with coupler fittings

• Smooth, easy to service front driveshaft with frontdifferential overload protection

• Low maintenance inline rear driveshaft eliminates theneed for U-joints

FWD

Transmission coupler

U-joints with grease fitting

• U-Joint grease fitting is accessed from underneath the vehicle after removing theskid plates

Top View

Side ViewRear

GearcaseFront

Differential

Engine input

Rear gearcase coupler

Return to TOC

66

Component:

At-a-Glance


Model: 2016 YXZ1000RTorque Limiter

• New clutch pack design torque limiter• 6 friction plates• 7 steel plates

• Smooth no maintenance front differential overloadprotection

FWD

Output Shaft

Snap Ring

Plate

Spring

Outer Splined Steel Plate

Inner Splined Friction Plate

Pack

Ring

End Pack

Case

• Slip Torque – 280~390 Nm

Return to TOC

67

Component:

At-a-Glance



Front Differential

• New front differential• 1HP-type servo motor is utilized• Gear ratio = (9/33)

• Proven Yamaha technology with incorporatedOn-Command® servo motor for effortless switchingfrom 2WD, 4WD or Diff-Lock

Input shaft

Oil drain bolt

1HP-type servo motor

Oil fill bolt

Oil level

• Oil capacityAssembly - 200cc (±20cc)Oil exchange - 180cc (±20cc)

• SAE 80 API GL-4 Hypoid gear oil is used

Removable bracket

Return to TOC

68

Component:

At-a-Glance



Rear Gearcase

• New rear gearcase• Gear ratio = (9/33)• External parking brake is adopted• Ring gear lock mechanism is integrated into gearcase design

• Oil capacityAssembly – 520cc (±30 cc)Oil exchange - 470 cc (±20cc)

• SAE 80 API GL-4 Hypoid gear oil is used

External parking brake disc mount

External parking brake caliper mount

Ring gear lock mechanism

Vent

Oil drain bolt

Oil fill bolt

Oil level

Removable bracket

• Proven Yamaha technology with incorporatedOn-Command® servo motor for effortless switchingfrom 2WD, 4WD or Diff-Lock

Return to TOC

69

Component:

At-a-Glance



CVJ Assemblies

• New front and rear constant-velocity joint (CVJ) assemblies• Plastic (PEEST) UJ and DOJ boots are adopted on the rear CVJ• PEEST boot on UJ and rubber (CR) DOJ boot are adopted on the front

CVJ

Front CVJDOJ = DOJ71A (inside joint) UJ = VUJ75 (wheel side) Shaft = Ø 19mm

Rear CVJDOJ = DOJ87L (inside joint) UJ = EBJ82M (wheel side) Shaft = Ø 21.2mm

• DOJ = double offset joint (plunging joint type)• UJ = undercut free joint (fixed joint type)• PEEST = Polyesterester• CR = Chloroprene Rubber (Neoprene)

Return to TOC

70

Component:

At-a-Glance



Gear Select

• Located on middle console• Shift rod is adopted

• Best ergonomics for the driver being located on themiddle console while still being easy to adjust

• The shifter rod adjustment can be accessed by removing the center console cover• Adjustment procedure on following page

FWD

Linkage rod

Center console mounted shifter

Engine shift mechanism

Center console mounted shifter

Return to TOC

71

Component:

At-a-Glance



Sequential Shift Pattern

• Manual 5 speed sequential transmission with reverse is adopted

• The reverse lock-out lever must be pulled to allow shifting into reverse

Return to TOC

72


Fig. 1

15º

STD position

Shift up position

ARM, SHIFT 2

Fig. 2

Clearance “A”2mm ± 1mm

Frame

Shift lever

Shifter Adjustment Procedure1. Rotate ARM, SHIFT 2 towards “shift up” side. <Fig. 1>

Note – Rotate the transmission propeller shaft to be certain the ARM, SHIFT 2 is in the most “shift up” position.2. Adjust shift rod so that clearance “A” is 2mm (±1mm) as seen in the diagram. <Fig. 2>3. Tighten shift rod lock nuts to specified torque.

Lock Nut Torque = 15Nm4. Shift through a few gears.5. Repeat step 1.6. Confirm shift rod adjustment clearance “A” is within specification.7. If out of adjustment, repeat steps 1~6.

Return to TOC

73

Component:

At-a-Glance



Reverse Lock-out

• Lever operated reverse lock-out is located on the steering console• Reverse lock-out cable is utilized

FWDReverse lock-out

cable

Center console mounted lever

Reverse lock-out cable adjusters

• The reverse lock-out adjustment can be accessed by removing the steering consolecover

Return to TOC

74

Component:

At-a-Glance



Reverse Lock-out (continued)

• Reverse lock out stopper is located on the shift drum

• The reverse lock-out adjustment can be accessed by removing the steering consolecover

Reverse lock-out cable

Reverse lock-out cable

Shift drum

Reverse lock-out stopper

Return to TOC

75

Component:

At-a-Glance



Steering

• New soft grip steering wheel with steel armature, PP substrate and softgrip over-mold

• New rack and pinion steering assembly is utilized• New EPS motor assembly is located on the steering column

• Comfortable steering wheel and optimal position fordriver to reduce effort and fatigue

• PP = Polypropylene

Rack and Pinion steering assembly

Steering shaft assembly

Steering assembly

EPS motor assembly

Armature (orange)

PP substrate (green)

Over-mold (black)

• Rack End Set is available as a separate service part

Rack end set

Tie rod end

Return to TOC

76

Component:

At-a-Glance



110mm

147m

m

EPS ECU

EPS ECU

• New Mitsubishi® EPS ECU assembly• Mounted under the center hood access

Return to TOC

77


EPS Diagnostic Wire

EPS Diagnostic Mode

1. Turn main switch ON2. Disconnect the EPS Diagnostic wire bullet

connector3. Touch the male terminal to the battery negative

post at least 5 times4. The EPS system will go into Diagnostic mode

and the EPS light in the multi-function meter willflash

5. Full details on the EPS fault codes anddiagnostic system will be in the service manual

EPS diagnostic mode wire

(attached to the YDT Diag Coupler with black tape)

Return to TOC

78

Component:

At-a-Glance



Steering Wheel Adjuster

• New quick adjust, gas-charged steering wheel height adjuster is adopted

• The new quick adjust steering wheel adjuster providesa wide range of adjustment for a variety of drivers

Fully raised Fully lowered

Gas-charged steering wheel adjuster

Steering wheel pivot bracket

Return to TOC

79

Component:

At-a-Glance



Steering Wheel Adjuster (Continued)

• Pull the release lever (towards the driver) and hold, move the steeringwheel to the desired position then release the lever

• The steering wheel is adjustable to any position within the range of travel -5.8 in (147mm)

Gas-charged cylinder release lever

Never adjust the steering wheel position while operating the vehicle, otherwise the steering wheel may suddenly change position, which may lead to an accident.

Return to TOC

80

Component:

At-a-Glance


Model: 2016 YXZ1000RFuel Tank and Pump

• New fuel tank located under passenger seat• B16-type fuel pump is utilized• 28P-type Pipe Assy. is used• Multi-layer design is adopted to eliminate the need for fluorination

• Fuel Tank Capacity:9.0 US Gal (34 L)

Fuel pump

1XD-type fuel capPipe Assy

Return to TOC

81

Component:

At-a-Glance


Model: 2016 YXZ1000R• Dedicated closed-in floorboards for both driver and passenger• Automotive inspired cockpit layout• Textured, angled floorboard with heel stop for the driver

Cab Layout

Textured floorboard

Passenger ‘dead’ pedal

Driver ‘dead’ pedal

Center storage

Adjustable steering wheel

Clutch pedal

Brake pedal

Throttle pedal

Center mounted shifter/switches/parking brake

lever/seat belt & helmet indicator

Glove box

Heel stop 2 cup holders

Driver floorboard Passenger floorboard

• A ‘dead’ pedal is typically a non-moving section of thefloorboard on which the driver rests their left foot

• It is the same height as the clutch pedal, allowing thedriver to move their foot from the ‘dead’ pedal to theclutch pedal easier

Return to TOC

82

Component:

At-a-Glance


Model: 2016 YXZ1000R• Automotive-type throttle, brake and clutch pedals are adopted• Dust cover is utilized

Driver Foot Pedals

• Automotive inspired layout provides the bestergonomics to control the throttle, brake and clutch

• Dust covers are utilized to help protect vital componentsfrom the outside elements

Driver ViewThrottle pedal

Brake pedal

Clutch pedal

Brake switch

Clutch switch

PP dust cover

Rubber dust cover

Return to TOC

83

Component:

At-a-Glance



Overhead Protection System

• Roll-over protection structure (ROPS) system*• 2 mounts for whip flags

• The roll-over protection structure and sun top are installed by the dealer

Side member

Side member

Sun top support

Cross member Whip flag mounts

Rear View

• *The ROPS system complies with the AmericanNational Standard for Recreational Off-HighwayVehicles, ANSI/ROHVA-1-2011 Standard

Return to TOC

84

Component:

At-a-Glance



Seat

• Driver seat location is adjustable – forward & back 3.5 in (90mm)• 3-point seat belt for both driver and passenger• Integrated shoulder bolsters

• Seats are ‘cut and sew’ design for highest quality fit andappearance

• Seat shape is tuned for a wide range of riders• Integrated shoulder bolsters for optimal support,

comfort, and secure feeling

3-point harnessTuned seat back

Shoulder bolsters are adopted

Bottom seat cushion is

removed with same steps as

1XP

‘Cut and sew’ style seat

Return to TOC

85

Component:

At-a-Glance



Driver’s Seat Adjuster

• New quick adjust driver’s seat is adopted• 8 positions possible• Forward / back adjustment range – 3.5 inches (90mm)

Seat adjust lever

• To adjust – pull up on the seat adjuster lever• Move to the desired position

New quick adjust seat

adjuster

Seat adjustment notches

Never adjust the seat position while operating the vehicle, otherwise the seat may suddenly change position, which may lead to an accident.

Return to TOC

86

Component:

At-a-Glance



Passenger Handhold

• Non-removable passenger handhold is adjustable with 3 positions4 inch (100mm) total adjustment range

• Adjustment method is the same as 1XP-type

• To adjust – open the wire lock tabs on each of the two grab handle securing pins• Remove both pins, adjust the grab handle to the desired position• Reinstall the pins and lock the wire lock back in place

3-position handholdShaped to provide goodergonomics for the passenger

Return to TOC

87

Component:

At-a-Glance



Dashboard Layout

• Forward mounted meter assembly• Automotive rotary style Diff-lock/Headlight/Ignition switches• Center mounted accessory outlet (12V/10A/120W max)

• Control, display and storage items are placed for themost favorable balance of ergonomics and function

Ignition switch

Headlight switch

Diff-lock switch

Center storageAccessory outlet Latching glove box

Helmet / seat belt light

Meter assembly

Parking brake

Shift lever

Return to TOC

88

Component:

At-a-Glance



Front A-arms

• Optimized caster, bump steer and Ackerman steering geometry throughout the travel and steering angle

New A-arm Design

• New design color matched A-arms• Bump steer = 7.2mm• Suspension ratio is optimized• Plastic CV guards

Front CV Guard

• Always inspect CV boots for cracks or tears as part of the pre-ride inspection

1G’ CompressExtend

Front CV Guard

Return to TOC

89

Component:

At-a-Glance



Front Suspension

• Ackerman steering geometry refers to the steering linkage designed to solve the problem of wheels on the inside and outside of a turn needing to trace out circles of different radius

• Caster = 6.80º• Trail = 1.33 in (33.7mm)

Side View

Return to TOC

90

Component:

At-a-Glance



Rear A-arms

• New design – super wide-span A-arm• Color matched A-arms• New spherical bearings are used on the lower A-arms• Suspension ratio is optimized

• Rear shocks are mounted as far out as possible to giveoptimum stroke and give the best possible camber tothe rear tires throughout the entire range of travel

FWD

Rubber boot

Spherical bearing

Circlip

New A-arm Design

• Always inspect CV boots for cracks or tears as part of the pre-ride inspection

Return to TOC

91

Component:

At-a-Glance



Rear A-arms (Continued)

• New design, color matched long A-arms• New spherical bearings are used on the lower A-arms• Suspension ratio is optimized

• Rear shocks are mounted as far out as possible to giveoptimum stroke and give the best possible camber tothe rear tires throughout the entire range of travel

Return to TOC

92

Component:

At-a-Glance



Anti-sway Bars

• Anti-sway bars are adopted both front and rear toachieve the desirable amount of body roll to give thevehicle the best combination of comfort and handling,especially when cornering

Front sway bar

• New sway bar for the front suspension• Sway bar is adopted for the rear suspension

Rear sway bar

• Check sway bar bushings on a regular basis for wear and replace as needed

Sway bar bushing

TipCheck for wear in this area

Self-adhesive reflective heat shielding is used on top of

the left rear sway bar mount (due to exhaust location)

Return to TOC

93

Component:

At-a-Glance



FOX® Shocks - Front

• New long travel FOX® Podium® RC2 shocks are adopted• Adjustable High/Low speed compression damping• Adjustable rebound damping• Adjustable spring preload

• Spring preload setting: distance AMinimum (soft): 428.2mm (16.86 in)Standard: 415.5mm (16.36 in)Maximum (hard): 402.8mm (15.86 in)

Spring installed length (A)

Eye to eye length

Com

pEx

tens

ion

Dam

ping

For

ce Front SuspensionShock Absorber Stroke 9.3 in (237.4mm)

Spring Rate 24~39.4 N/mm*Spring Installed Length 16.4 in (415.5mm)

Eye to Eye 25.8 in (656.5mm)Piston Outside Diameter 2.3 in (57.2mm)

• * Dual rate spring (progressive)• Preload adjusting nut tightening torque:Locknut:41 Nm (4.1 m·kg, 30 ft··lb)

Return to TOC

94


Dual Speed Compression (DSC)

Adjuster

Rebound Adjuster

2.5” 6061-T6Aluminum Body

7/8” Induction Hardened Steel Shaft

Adjustable SpringPreload

2.5” 6061-T6Aluminum Reservoir

ProgressiveSpring

DX Bearings (both mounts)

Note: Aluminum construction allows for reduced weight and improved heat dissipation

Return to TOC

95

Component:

At-a-Glance



FOX® Shocks - Rear

• New long travel FOX® Podium® RC2 shocks are adopted• Adjustable High/Low speed compression• Adjustable rebound damping• Adjustable spring preload

• * Dual rate spring (progressive)

Spring installed length (A)

Eye to eye length

Com

pEx

tens

ion

Dam

ping

For

ce Rear SuspensionShock Absorber Stroke 10.7 in (272.9mm)

Spring Rate 28.4~52.5 N/mm*Spring Installed Length 19.1 in (484.1mm)

Eye to Eye 32.1 in (815.2mm)Piston Outside Diameter 2.3 in (57.2mm)

Spherical bearing

Spherical bearing

• Spring preload setting: distance AMinimum (soft): 496.8mm (19.56 in)Standard: 484.1mm (19.06 in)Maximum (hard): 471.4mm (18.56 in)

• Preload adjusting nut tightening torque:Locknut:41 Nm (4.1 m·kg, 30 ft·lb)

Return to TOC

96


Shock Name: 2.5” Podium RC2 with BOC

Dual Speed Compression (DSC)

Adjuster

Rebound Adjuster

2.5” 6061-T6Aluminum Body

7/8” Induction Hardened Steel Shaft

Adjustable SpringPreload

2.5” 6061-T6Aluminum Reservoir

ProgressiveSpring

Teflon Lined COM 10 Spherical Bearings

(both mounts)

Bottom Out Cup (BOC)

Position Sensitive Damping

Technology

Note: Aluminum construction allows for reduced weight and improved heat dissipation

Return to TOC

97

Component:

At-a-Glance



Rear Shocks - Rear (continued)

• FOX® Bottom-Out Control (BOC) is adopted on the rear shocks

• Allows the shocks to be tuned for improved small bumpcompliance in the upper portion of the stroke, referred toas the Ride Zone

• Maintain the ability to absorb the big bumps effectively

BOC Secondary Piston

Primary Piston

Ride Zone• Oil will bypass the secondary piston• The primary piston provides the damping for the

majority of the stroke

BOC Zone (approx. final 25% of travel)• The secondary piston enters the bottom-out cup• The primary and secondary piston provides the

damping force

BOC shim stack

Return to TOC

98

Component:

At-a-Glance



FOX® Shocks – Front & Rear

• Adjustable High/Low speed compression damping• Adjustable rebound damping• Adjustable spring preload

High speed (hex head)

& Low speed (screw driver slot)

compression damping adjusters

Rebound damping adjuster

Spring preload adjustment

• High speed and Low speed refers to the rate ofmovement of the shaft inside the shock, not vehiclespeed

Return to TOC

99


Front Suspension Damping Setting Chart

Rebound damping setting:Minimum (soft): 26 click(s) in direction (b)*

Standard: 12 click(s) in direction (b)*

Maximum (hard): 1 click(s) in direction (b)**

* Starting with the adjusting screw fully turned in direction (a)

High speed compression damping setting:Minimum (soft): 4 turns out from the fully turned in position

Standard: 2 turns out from the fully turned in position

Maximum (hard): Adjusting bolt fully turned in

Low speed compression damping setting:Minimum (soft): 4 turns out from the fully turned in position

Standard: 1 ½ turns out from the fully turned in position


Return to TOC

100


Rear Suspension Damping Setting Chart

Rebound damping setting:Minimum (soft): 26 click(s) in direction (b)*

Standard: 8 click(s) in direction (b)*

Maximum (hard): 1 click(s) in direction (b)**

* Starting with the adjusting screw fully turned in direction (a)

High speed compression damping setting:Minimum (soft): 4 turns out from the fully turned in position

Standard: 2 turns out from the fully turned in position


Low speed compression damping setting:Minimum (soft): 4 turns out from the fully turned in position

Standard: 1 ½ turns out from the fully turned in position


Return to TOC

101

Component:

At-a-Glance



Brakes (Front and Rear)

• Nissin® 17.5 x 18mm dual-chamber type master cylinder• New front Nissin® dual 32mm piston calipers• New rear Nissin® dual 27mm piston calipers• 9.6 inch (245mm) diameter rotors are adopted

Brake pipe junction

Frame

Front brake caliper

Rear brake caliper

Master cylinder

• Use DOT 4 Brake Fluid

Return to TOC

102


To both front brake calipers

To both rear brake calipers

FWD

Front brake pressure chamber

Secondary piston

Rear brake pressure chamber

• The dual-chamber type master cylinder shares the brake fluid reservoir, but separates the front and rearbrake systems into 2 pressure chambers when the brakes are applied

• It is critical to bleed both the front and rear brake systems whenever the brake pedal feels ‘soft’ since it isdifficult to distinguish which system might have air-bubbles trapped

Primary piston

Dual Master Cylinder

Return to TOC

103

Component:

At-a-Glance



Knuckles

• New design knuckles are adopted• New style wheel bearings are utilized

Rear Knuckle Front Knuckle

Grease fitting

Grease fitting

Return to TOC

104

Component:

At-a-Glance



Tires

• 27-inch tires provide excellent ground clearance,traction, durability, comfort and steering precision

• Yamaha exclusive 27-inch Maxxis® Bighorn™ 2.0 tires• Radial construction

• Always set tire pressure to recommended spec and inspect for cracks or punctures during“Pre-Ride Inspection”

Front Rear

Tire Size 27x9.00R14 27x11.00R14

Ply Rating 6

Air Pressure See next page

Tire TypeMaxxis®

Bighorn™ 2.0 MU09

Maxxis®

Bighorn™ 2.0 MU10

Front

Rear

Return to TOC

105


Vehicle Loading and Tire Air Pressure Chart

Return to TOC

106

Component:

At-a-Glance



Wheels

• New cast aluminum wheels (all models / bead lock rims shown)• SE and 60th anniversary models adopt bead lock rims

• Cast aluminum rims provide an aggressive look todifferentiate from the competitors

• Optimized offsets help complement the handling toprovide a nimble yet stable feel

• Bolt PatternFront - 4 x 110Rear - 4 x 110

Offset 48mm

Front Rear

Offset 34mm

Rim Size14 x 6.5

Rim Size14 x 8.0

Bead Lock RimBead Lock Rim

Standard Rim Standard Rim

Return to TOC

107

Component:

At-a-Glance


Model: 2016 YXZ1000RWheels (Bead Lock)

• New 14 inch bead lock wheels are adopted (60th and SE models only)• Lock plate is secured by 15 fasteners

Cast Aluminum Rim Lock Plate M6 Fasteners

Cast Aluminum Rim Lock Plate

Tire Bead Channel

• The M6 fasteners will need to be re-torqued as a periodic maintenance item

Return to TOC

108


Assembling the Bead Lock Rim

1. Assemble tire onto the rim.

2. To seat the outside bead of the tire place the lock plate onto the rim (over the bead) and start the fasteners.

3. Starting at No.1 in the illustration to the right, torque the fasteners to 5 Nm following the pattern to No.15.

4. Using the same pattern torque the fasteners to 12Nm.

5. Inflate the tire to 128 kPA (18.5 psi) to seat the inside bead.

6. Torque the fasteners in the same pattern as above to 17Nm.

7. Set tire to recommended tire pressure. (refer to page 106)

Return to TOC

109

Component:

At-a-Glance



Cargo Bed

• Polypropylene construction• Fixed position (bed does not tilt) with 300 lb cargo capacity• Storage compartment• 4 steel tie down points

• Strong, light and durable construction• 4 steel tie down points welded to the frame for securing

gear in rough terrain

Steel tie down points

Cargo Bed Capacity 300 lb / 136 kg

Total Vehicle Capacity 728 lb / 330 kg

Cargo bed coverStorage compartment

Storage compartment

FWD

Return to TOC

110

Component:

At-a-Glance



Sun Top

• Polypropylene construction• Standard component on all models

• Installed by dealer• Use a square tipped driver to install the sun top

bracket screws

FWD

Bottom View

Sun top support

Return to TOC

111

Component:

At-a-Glance


Model: 2016 YXZ1000RMeter Assembly

• Analog tachometer• Digital speedometer• Digital gear indicator with programmable shift indicator light

Shift Indicator Light Operating range: more than 9500r/minUser adjustable setting: turn on rpm

turn off rpm

Modes: ON, OFF or BLINK

Tachometer red zone

10,500 ~12,000

Gear position indicator N,R,1~5 Speedometer

KMH or MPH

Shift indicator light

Odometer/Trip

Fuel meter

Clock/Hour/Voltage

Engine coolant temperature indicator

SELECT button

MODE button

RESET button

Check Engine Light

Parking brake indicator

Reverse/Neutral IndicatorsDiff-Lock indicator

EPS indicator

Connector <Meter Side>

1 BATT+ 5 CAN-LO

2 IGN+ 6 CAN-HI

3 GND 7 FUEL

4 EPS 8

• Engine Coolant Temperature IndicatorIndicator = off 32º~250ºF (0º~121ºC)Indicator = blue below 32ºF (0ºC) Indicator = red above 251ºF (122ºC)

Return to TOC

112

Component:

At-a-Glance



• Wattagelow beam: 12V / 6.2Whigh beam: 12V / 12.4W

Headlight

• Four eyes headlight design is adopted• LED headlights are utilized – 2UD-type

• LED headlights provide great illumination with lowpower consumption

• LED headlights are considered semi-permanent with anextremely long service life

Low beam (upper side only)

High beam (upper & lower side)

LED Chip

HI beam = Yellow Low beam = Green Ground = Black

Connector <Headlight Side>

Return to TOC

113

Component:

At-a-Glance



• Wattage:brake light: 12V / 3.9 Wtail light: 12V / 0.5W

Tail Light

• LED tail light is adopted – 1S3-type

• LED tail light - high visibility with low powerconsumption

• LED tail lights are considered semi-permanent with anextremely long service life

Stop = YellowTail light = Blue Ground = Black

Connector <Taillight Side>

Return to TOC

114

Component:

At-a-Glance



• Stator Output14V / 33.7A / 472W @ 5000 rpm

AC Magneto Assembly

AC Magneto

Reluctors

Crankshaft Position Sensor

• Mitsubishi® magneto assembly• Mounted directly at the rear of the engine

0

5

10

15

20

25

30

35

40

1 2 3 4 5 6 7 8 9 10 11X 1,000 rpm

Amps

• 22 projections on magneto rotor, with ‘gap’ to provideindexing function to determine exact piston position

Return to TOC

115

Component:

At-a-Glance



Ignition Coil

Ignition Coil

• New Mitsubishi® ignition coils• Each coil is mounted using 2 fasteners

• Spark Plug: NGK CR9EBGap: 0.028-0.031 in (0.7-0.8mm)

Dust Seal

• Dual fasteners for each coil to help seal out the mudand dirt encountered on this type of vehicle

Return to TOC

116

Component:

At-a-Glance



84.5mm

70m

m

90m

m

32m

m

Rectifier / Regulator

Rectifier Regulator Assembly

• 1D7-type rectifier regulator is adopted

Return to TOC

117

Component:

At-a-Glance


Model: 2016 YXZ1000RBuzzer

• 2MB-type buzzer is adopted• Buzzer will sound if driver seat belt is not latched or parking brake is

engaged and a signal is received from speed sensor

ECU

Speed sensor

Parking brake switch

Buzzer

Meter assembly

Batt.

Seat belt switch

Buzzer located on steering column

• Buzzer is located on the steering column

Return to TOC

118

Component:

At-a-Glance



Remove the center console cover

Center Console (Electrical Components Access)

• Major electrical components are located under the center console cover

Majorelectrical

components

Engine air intake

• See next page for details on electrical component location

Return to TOC

119


Removing & Reinstalling Center Console - Rubber Grommets

REMOVING• Remove the center console cover (1) by pulling it up as

shown

• After removing account for the two rubber grommets (2),they may come off with the cover, or fall out of place

REINSTALLING• Make sure the two rubber grommets (2) are in

place and lubricate with YAMALUBE® SILICONESPRAY PROTECTANT & LUBRICANT(if the grommets are not lubricated, the posts on thecover may push them down, out of place when tryingto install the cover)

• Place the cover in the original position and pushthe posts into the rubber grommets

2

Return to TOC

120


Battery GS U1-H11L

ECU

Starter Relaywith15A FI fuse

8DM Relays

Hi Beam Headlight Relay

Low Beam Headlight Relay

Fan Relay

Fuel System Relay

Load Control Relay(power into fuse box)

Fuse Box w/Auxiliary DC jack fuse (Terminal)

Lean Angle Sensor

40A Main Fuse

40A EPS Fuse

4WD Relay 1

4WD Relay 2

Fuse Box

Starter Relay

15A FI fuse 15A Spare fuse

TERM

INAL

10A

121

Component:

At-a-Glance



ECU

• New Mitsubishi® ECU is adopted• CAN Bus communication is utilized• YDT is adopted

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 1718 19 20 21 22 23 24 25

26 27 28 29 30 31 32 33 34

PIN # CODE NAME PIN # CODE NAME1 VB Battery Voltage 24 SP Speed Sensor2 DF12 Differential switch 12 25 DFL2 Differential Lock Rotary Switch 23 DFL1 Differential Lock Rotary Switch 1 264 WT Water Temperature 27 CT10 YDT Communication 5 PB2 Intake Pressure Sensor 2 28 DL12 Differential Servo Position 26 AT Atmospheric Temperature Sensor 29 SB Seat Belt Switch7 VCC Sensor Power Source 308 CRK Crank Position Sensor 31 TP Throttle Position Sensor9 CANL Can Bus (Low) 32 PB1 Intake Pressure Sensor 1

10 CGND1 Control System Ground 1 33 OPS Oil Pressure Switch11 DF11 Differential switch 1 3412 VM Battery voltage Monitor13141516 SGND Sensor System Ground17 CANH Can Bus (High)18 CGND2 Control System Ground 21920 DL11 Differential Servo Position 121 NL Neutral Switch22 GP Gear Position Sensor23 LA Lean Angle Sensor

• The ECU connectors are the both same size and number of connecting wires• Note the number and location of the indexing marks (circled above)• Right side connector has two index ribs at the bottom, the left connector has only one rib

Return to TOC

122

Component:

At-a-Glance



ECU

• New Mitsubishi® ECU is adopted• CAN Bus communication is utilized• YDT is adopted

35 36 37 38 39 40 41 42 43

44 45 46 47 48 49 50 5152 53 54 55 56 57 58 59

60 61 62 63 64 65 66 67 68

PIN # CODE NAME PIN # CODE NAME35 PGND1 Power System Ground 1 47 SBPL Seat Belt Pilot Lamp36 PGND2 Power System Ground 2 48 BZ Parking Brake Buzzer37 IJ3 No.3 Cylinder Injector 49 TC Tachometer Drive38 ISC2 Idle Speed Control Stepping motor 2 50 ST Start Switch39 ISC3 Idle Speed Control Stepping motor 3 51 AI Air Induction (AI) Relay40 ISC4 Idle Speed Control Stepping motor 4 52 IG3 Ignition No.341 ISC1 Idle Speed Control Stepping motor 1 5342 5443 55 MR Main Relay44 IG1 Ignition No.1 56 RFR Radiator Fan Relay45 DFR1 Differential Lock Relay 1 57 BRK2 Park Brake Switch46 DFR2 Differential Lock Relay 2 58 BRK Brake Switch

59 SR Starter Relay Control Output60 IG2 Ignition No.261 IJ2 No.2 Cylinder Injector62 IJ1 No.1 Cylinder Injector636465 DL13 Differential Servo Position 366 CL Clutch Switch6768 BAT Battery Voltage

• The ECU connectors are the both same size and both have 34 pin locations• Note the number and location of the indexing marks (circled above)• Right side connector has two index ribs at the bottom, the left connector has only one rib

Return to TOC

123

Component:

At-a-Glance



Yamaha Diagnostic Tool (YDT)

• Yamaha Diagnostic Tool (YDT) is adopted• Diagnostic service tool connector is located under the center console cover

• K-line communication is utilized• FFD is not adopted

• B/W = ground• R/W = battery voltage (hot, before main switch)• Y/W = data line• Diag Mode in not available through multi-function meter assy.

Return to TOC

124


Yamaha Diagnostic Tool (YDT) – Logging / Monitor Mode Systems

Return to TOC

125

™ACCESSORIESACCESSORIES

™Check out the full line of Yamaha Genuine Accessories at ShopYamaha.com

NEW! Folding WindshieldThe YXZ1000R Folding Windshield provides protection and versatility for changing weather conditions all thanks to its convenient folding design. Fold the hard-coated polycarbonate panels up, down, or simply tip-out for various climate conditions.

• When closed – lower cowl provides air movement throughout the cabin with an open vent in the center• Windshield is sealed against an injection-molded support on the fender and a foam seal on the roof when in

the closed position, preventing water from entering the cab• Built-in kickstands for tip-out functionality open the bottom 2" for airflow• Provides protection from wind, rain, leaves, branches, brush, and other trail debris• Superior scratch resistance• Will not shatter like acrylic windshields

Fits ’16 YXZ1000R

2HC-F83J0-V0-00

Available early October 2015

NEW! Wind DeflectorThe YXZ1000R Wind Deflector is made from hard-coated polycarbonate that offers superior scratch resistance and will not shatter like acrylic windshields.

• Deflector helps divert wind• Comes with injection-molded lower cowl

Fits ’16 YXZ1000R

2HC-F83M0-V0-00 Available early October 2015

NEW! Center Mount Mirror by Assault IndustriesPart of Assault Industries Stealth Mirror Collection, this rear view mirror is built for strength and durability.

• Housing is made of polymer for strength, durability and light weight• The included Assault Industries® 1.5" bracket is CNC-machined from 6061 T6 aluminum• Trail-tested to ensure it’ll dominate the harsh rides you’re sure to put your YXZ1000R through

Fits ’16 YXZ1000R

B85-F6206-V0-00 Available late September 2015


NEW! Bomber Side Mirror Set by Assault IndustriesThis Bomber Series Side Mirror Set features a breakaway ball joint and was designed for the everyday driver or even the toughest racer out there.

• Great visibility and adjustability• Housing is made from high-impact polymer to keep the mirror light but strong; design enforces the strength

of the mirror housing• Designed to work on any 1.75" roll bar• Available in Black and White faceplate options to help you customize your ride• Sold in pairs

Fits ’16 YXZ1000RBlack*DBY-ACC56-51-51

White*DBY-ACC56-51-52

*Available late September 2015

NEW! Desert Front Grab Bar with Winch PlateThis Desert Front Grab Bar is machined from durable, welded steel sheet and tube. It’s designed to add protection to the front end of the YXZ1000R from rocks, trees, branches, and other debris. Includes a winch plate that gives you the ability to mount up a Vantage 3000 Winch by WARN® (sold separately).

• Lightweight, durable, long-lasting black satin powder-coated finish• Utilizes stock mounting locations and hardware• Enhances the rugged sport styling of YXZ1000R• Winch Wiring Kit required if mounting winch to this Grab Bar (Winch Wiring Kit and winch both sold

separately)

Fits ’16 YXZ1000R

2HC-F84L0-T0-00

Available November 2015

NEW! Desert Front Grab Bar (no Winch Plate)This Desert Front Grab Bar is machined from durable, welded steel sheet and tube. It’s designed to add protection to the front end of the YXZ1000R from rocks, trees, branches, and other debris.

• Lightweight, durable, long-lasting black satin powder-coated finish• Utilizes stock mounting locations and hardware• Enhances the rugged sport styling of YXZ1000R

Fits ’16 YXZ1000R

2HC-F84L0-V0-00 Available early October 2015


NEW! Trail Front Grab Bar with Winch PlateThis Trail Front Grab Bar is machined from durable, welded steel sheet and tube. It’s designed to add protection to the front end of the YXZ1000R from rocks, trees, branches, and other debris. Includes a winch plate that gives you the ability to mount up a Vantage 3000 Winch by WARN® (sold separately).

• Lightweight, durable, long-lasting black satin powder-coated finish• Utilizes stock mounting locations and hardware• Enhances the rugged sport styling of YXZ1000R• Provides protection for headlights• Winch Wiring Kit required if mounting winch to this Grab Bar (Winch Wiring Kit and winch both sold

separately)

Fits ’16 YXZ1000R

2HC-F84L0-S0-00

Available November 2015

NEW! Rear Grab BarThis Rear Grab Bar is designed to help protect your YXZ1000R’s rear area and fit the unit’s styling perfectly.

• Utilizes two mounting points and two clamps for a strong mount• Extends down the frame tube for additional coverage• Made of 0.08" thick steel tubing and sheet metal• Black satin powder-coat finish helps ensure long life

Fits ’16 YXZ1000R

2HC-F85E0-V0-00


NEW! OverfendersThis 4-piece Overfender Set adds protection from the elements while also enhancing the overall look of the YXZ1000R.

• Made from a durable, thermoformed plastic• Provides additional protection from mud and water• Designed to integrate with the sporty styling of the YXZ1000R• Bolts to the unit with stainless steel hardware for secure attachment

NOTE: Drilling of fenders required for installation.

Fits ’16 YXZ1000R

2HC-F15E0-V0-00

Available October 2015


NEW! Rear WindowThis Rear Window is made of SurLast® 600D all-weather, mildew, and fade-resistant fabric with a clear polished vinyl window that will not yellow over time. Our window will provide years of added protection from wind, rain, and debris. Other features include:

• Zippered storage compartment between the seats• Clear window can be rolled up for air movement in the cab• Prevents “dust swirling” from the back of vehicle• Solution dyed – this is the best method of dyeing; the dye solution is 100% through the thread, not just on

the outside

Fits ’16 YXZ1000RBlack2HC-K750A-V0-00

Available late September 2015

NEW! Spare Tire MountThis rotating Spare Tire Mount allows the transport of a spare wheel and tire for long rides or rough terrain; giving you peace of mind that you’ve got a back-up if needed.

• Swivels outward to access the accessory Cargo Box (sold separately) without removing tire• Has a special feature that keeps the mount locked in the open position when you have it swiveled outward,

so you can freely access the bed area• Securely locks in the closed position• Secures spare tire with a wing-type speed bolt and a billet aluminum cone in the center of the wheel to fit a

variety of wheels• Steel construction with black satin powder-coated finish• Can mount up to a 30" tire• Matches the sporty styling of the YXZ1000R• Wheel and tire not included

Fits ’16 YXZ1000R

2HC-K75J0-V0-00

Coming Soon!

NEW! Rear Cargo BoxThis Rear Cargo Box lets you secure your essentials when venturing out in your YXZ1000R.

• Capacity: approximately 4.5 cubic feet• Constructed of tough, linear, low-density polyethylene• Water and dust-resistant• Lockable lid (includes space for an optional padlock)• Battery Tray inside for optional accessory 2nd Battery Kit (sold separately)• Non-reflective surfaces• Helps prevent cargo contamination• Lid stays open past 90° angle position for easy access to cargo• Can function as a cooler (if 2nd Battery Kit is not mounted inside)• Uses OEM hardware

Fits ’16 YXZ1000R Black2HC-F83P0-V0-00 Available October 2015


• Fully sealed, three-stage planetary gear train, composite gear housing with metal gears• 50' of 5/32" wire rope and roller fairlead• Durable corrosion-resistant black finish on hook, tie rods, and body• Patented roller disc brake for outstanding control while winching• 5-year mechanical and one-year electrical limited warranty from WARN®

• Winch Wiring Kit (2HC-F28M0-V0-00) required for winch installation• One of two accessory Front Grab Bar options required for winch mounting: Desert Front Grab Bar with Winch

Plate (2HC-F84L0-T0-00) or Trail Front Grab Bar with Winch Plate (2HC-F84L0-S0-00), sold separatelyNOTE: Winch cannot be mounted on the YXZ1000R’s stock front grab bar

Fits ’16 YXZ1000R

SSV-F740C-T0-00

NEW! Winch Wiring KitThis wiring kit is required for use with the Vantage 3000 Winch by WARN® (sold separately). Winch also requires one of two accessory Front Grab Bar options for mounting: Desert Front Grab Bar with Winch Plate (2HC-F84L0-T0-00) or Trail Front Grab Bar with Winch Plate (2HC-F84L0-S0-00), both sold separately.

Fits ’16 YXZ1000R

2HC-F28M0-V0-00

Available Late September 2015

NEW! YXZ1000R Storage CoverHelps protect your investment from the elements during storage.

• Constructed of black ClimaShield® 300D, all-weather fabric• This custom-fit storage cover secures to the unit with elastic around the perimeter of the bottom edge• Cover fits with all installed accessories too• Features the YXZ1000R logo on the sides and Yamaha Tuning Fork logo on the front• Solution dyed – this is the best method of dyeing; the dye solution is 100% permeated through the thread,

not just on the outside

Fits ’16 YXZ1000R

2HC-F81A0-V0-00


Vantage 3000 Winch by WARN®

WARN® Industries, a leader in the winch business, worked with Yamaha to create the Vantage 3000 specifically for Yamaha customers. This winch’s 3,000 lb. capacity is suitable for all Yamaha Side x Side models. Features include:


NEW! Radiant LED Light BarsThis new light bar is a great addition to your YXZ1000R. Riding at night and in low-light conditions becomes safer and more comfortable with the amount of additional light this bar kicks out.

• 5W Cree® LEDs 0.4W LED halos• 50,000 hour life span• Aluminum extruded housing• Custom Yamaha end caps• Flexible mounting base with lateral mounting capability• Vehicle wiring harness with roof grommet• Illuminated 2-position switch• Low power consumption• Beam configuration: 4 Flood, 8 Spot, 4 Flood (27"), 2 Flood, 4 Spot, 2 Flood (15")• Dimensions: 27" Light Bar - 27.56"W x 2.48"H x 3.89"D, 15" Light Bar – 14.96"W x 2.48"H x 3.89"D• Includes mounts• Accessory Alternator Kit (2HC-H1200-V0-00) required for installation of the 27" Light Bar option• Optional Switch Panel Kit (2HC-H2570-V0-00) also available separately

NOTE: Drilling of Sun Top required for installation.

Fits ’16 YXZ1000R

a. 27" Light Bar*

2HC-H4104-R0-00b. 15" Light Bar*2HC-H4104-M0-00*Available early October2015

NEW! High Output HALO LED Light BarsThis all new LED light bar is the industry’s first and only SxS Halo LED Light Bar. The signature LED halos provide vehicle illumination and indication in nearly all riding situations.

• 10W Cree® LEDs 0.4W LED halos• 50,000 hour life span• Aluminum extruded housing• Custom Yamaha end caps and front covers• Flexible mounting base with lateral mounting capability• Vehicle wiring harness with roof grommet• Illuminated 3-position switch• Low power “Halo Only Mode”• Halos can be used as daytime running lights (“optional always on”)• Offers increased vehicle visibility on the trail and both near and distance illumination• Beam configuration: 4 Flood, 8 Spot, 4 Flood (27"), 2 Flood, 4 Spot, 2 Flood (15")• Dimensions: 27" Light Bar - 27.56"W x 2.48"H x 3.89"D, 15" Light Bar – 14.96"W x 2.48"H x 3.89"D• Includes mounts• Accessory Alternator Kit (2HC-H1200-V0-00) required for installation of either of these two light bar options• Optional Switch Panel Kit (2HC-H2570-V0-00) also available separately

NOTE: Drilling of Sun Top required for installation.

Fits ’16 YXZ1000Ra. 27" Light Bar*2HC-H4104-T0-00

b. 15" Light Bar*2HC-H4104-P0-00

*Available early October2015

a.

b.

a.

b.


• Kit includes a 12V DC outlet and removable covers for any unused ports• Constructed of lightweight, shatterproof polycarbonate• Graphic design complements the YXZ1000R styling• Same kit that comes standard with Yamaha’s accessory Overhead Audio System (2HC-H81C0-V0-00),

sold separately

Fits ’16 YXZ1000R

2HC-H2570-V0-00


NEW! Accessory Light KitsThese 2.5" accessory lights are a great addition to point light where your headlights can’t reach. These 10W LEDs shine an extremely bright beam while drawing very little power. Their compact size makes them versatile and allows you to mount them just about anywhere on your YXZ1000R.

• Available in Spot (long distance) or Flood (wide) beam patterns• Can be mounted on any flat area• 360° adjustability• Optional Accessory Mount Clamps (2HC-F34A0-V0-00) also available separately• Sold in pairs and includes a harness and switch

Fits ’16 YXZ1000R

a. Spot*

2HC-H4104-V0-00b. Flood*2HC-H4104-L0-00*Available early October2015

NEW! Accessory Mount ClampsThese 1.5" clamps allow you to rigidly mount additional accessories (that use 6mm bolts) to the overhead frametubes (directly beneath top).

• Perfect for the Accessory Light Kits (2HC-H4104-V0-00 and 2HC-H4104-L0-00)• Black anodized aluminum material for long-lasting durability

Fits ’16 YXZ1000R

2HC-F34A0-V0-00


NEW! Switch Panel KitThis switch panel allows you to install Carling®-style rocker switches. Recommended for use with the Yamaha accessory light bars and/or lights and works with other electrical accessory add-ons as well.

b.

a.


• Features a modular design• Fiberglass construction and marine-grade components withstand harsh trail conditions• Includes housing, speaker, amplifier, and stainless steel mounting hardware• Designed to be used with Overhead Audio System and Rear Speaker Pods (sold separately)

NOTE: Cutting required; dealer installation recommended.

Fits ’16 YXZ1000R

2HC-H81D0-T0-00


• These speakers endure harsh conditions thanks to their marine-grade fiberglass construction• Compatible and designed to be used with our Overhead Audio System and Powered Subwoofer

(sold separately) or most other audio systems• Set includes stainless steel mounting hardware• Mounts behind driver and passenger utilizing the overhead protection bars

Fits ’16 YXZ1000R

2HC-H81D0-V0-00


NEW! Powered SubwooferThis 10" powered subwoofer is designed to deliver the best sound quality and bass response.

NEW! Overhead Audio SystemYamaha and SSV Works® collaborated on the design for this Overhead Audio System for the YXZ1000R. Designed to withstand harsh conditions, the system preserves valuable cargo space by mounting two speakers overhead and utilizes the dash area for the audio controls. Other features include:

• Waterproof, marine-grade two-way 6.5" speakers• Audio control on the dash (volume, track, forward/back, play/pause) and 3.5mm AUX input for MP3 or Sirius

XM® Radio, and a 12V DC charge port• Bluetooth® connectivity• SSV Works® output connector for system expansion• Includes accessory Switch Panel Kit• To further enhance this system, add on the accessory Rear Speaker Pods and Powered Subwoofer

(sold separately)

Fits ’16 YXZ1000R

2HC-H81C0-V0-00


NEW! Rear Speaker PodsThese simple yet durable modular rear speakers crank out quality sound and bass response.


NEW! Alternator KitThis alternator is a great addition to the YXZ1000R, ensuring your battery stays charged while running different electrical accessories such as lights and stereos. Kit includes:

• Alternator and mount• Wiring• Belt and pulley• Dust Cover• New oil lines (must relocate)• All necessary hardware• This Alternator Kit is required for use if either the 27" or 15" High Output HALO LED Light Bar or 27" Radiant

LED Light Bar (sold separately) is installed on the unitNOTE: Dealer installation recommended.

Fits ’16 YXZ1000R

2HC-H1200-V0-00

Coming Soon!

NEW! Rekluse® ClutchThis auto-clutch system allows you to operate the manual transmission on the YXZ1000R with ease. The Rekluse® clutch eliminates the need to use the clutch pedal in most operating conditions, adding convenience without reducing performance.NOTE: Dealer installation recommended.

Fits ’16 YXZ1000R

2HC-E63B0-V0-00


NEW! 2nd Battery KitThis 2nd Battery Kit enables the use of two batteries, saving the main battery for essential functions like starting. If both batteries need charging, the main battery is charged first. Use with 12V accessories such as winches, lights, stereos, and more.

• Waterproof design• Includes cut-to-length wiring and connectors• Includes a sealed 2nd battery• Easy to install• Can be mounted inside the accessory Rear Cargo Box (sold separately) or alternatively, can be mounted

directly in the bed using the accessory 2nd Battery Mount Kit (sold separately) which includes battery box

Fits ’16 YXZ1000R2nd Battery Kit2HC-H21B0-V0-00

Available September 2015

2nd Battery Mount Kit2HC-H212A-V0-00



Vantage 3000 Winch by WARN® SSV-F740C-T0-00

Pro Vantage 2500 Winch by WARN® ABA-F740C-V0-00

Vantage 2000 Winch by WARN® ABA-F740C-T0-00

WARN® Neoprene Winch Cover GYT-0SS56-00-07

WARN® Wireless Winch Remote Control GYT-0SS56-00-05

Flashlight Mount 5B4-K830X-V0-00

Water Bottle Holder 5B4-K83A0-V0-00

LED Dome Light SSV-5B411-20-00

Cargo Bed Net by Speed Industries™ (30" x 28") SSV-0SS56-51-44

Micro-Start XP-10 PPS by Antigravity Batteries™ DBY-ACC56-25-02

Micro-Start XP-1 PPS by Antigravity Batteries™ DBY-ACC56-24-57

Micro-Start Mini XP-5 by Antigravity Batteries™ DBY-ACC56-25-01

Current Yamaha Accessories Also Available for YXZ1000R

NEW! GYTR® Gauze Air FilterThe GYTR High-Flow Gauze Air Filter offers increased airflow and excellent filtration for improved performance. Filter is washable and reusable. Service with Yamalube® Gauze Filter Cleaner (ACC-FLTER-CN-CS).NOTE: Dealer installation recommended.

Fits ’16 YXZ1000R

2HC-E41D0-V0-00

Available late October 2015

NEW! GYTR Foam Air FilterThe GYTR Multi-Stage Foam Air Filter has a special two-stage design for maximum airflow and superior filtration for greater engine protection. Service with Yamalube Bio-degradable Foam Air Filter Oil & Cleaner Kit (ACC-BIFMF-LT-KT) or Foam Filter Oil (ACC-FOAMF-LT-ER).

Fits ’16 YXZ1000R

2HC-E41C0-V0-00

Available late October 2015

™

Manufacturer’s suggested retail prices are shown. Prices may vary due to supply, freight, etc. Actual prices set by the dealer. Product and specifications subject to change without notice. Availability subject to production, stocking, and demand. Side x Side models are recommended for use only by operators 16 years and older with a valid driver’s license. YXZ1000R recommended for experienced operators only. Always wear your seat belt, helmet, eye protection and protective clothing. Never drink and ride. Professional riders depicted on a closed course.

This document contains many of the valuable trademarks and service marks owned and used by Yamaha throughout the world. The document may also contain references to other company, brand, and product names that may be the trademarks/service marks of their respective owners. These company, brand, and product names are used herein for identification purposes only, and references to any names, marks, products, or services of third parties do not constitute or imply endorsement, sponsorship, or recommendation of the third party or the products or services. ©2015 Yamaha Motor Corporation, U.S.A. All rights reserved.

Side x Side models are recommended for use only by operators 16 years and older with a validdriver’s license. YXZ1000R recommended for experienced operators only. Always wear yourseat belt, helmet, eye protection and protective clothing. Never drink and ride. Professionalriders depicted on a closed course.This document contains many of the valuable trademarks and service marks owned and usedby Yamaha throughout the world. The document may also contain references to other company,brand, and product names that may be the trademarks/service marks of their respective owners.These company, brand, and product names are used herein for identification purposes only,and references to any names, marks, products, or services of third parties do not constitute orimply endorsement, sponsorship, or recommendation of the third party or the products orservices. ©2015 Yamaha Motor Corporation, U.S.A. All rights reserved.

2016 yxz1000r-service-guide-final-ver-2

Automotive

Transcript of 2016 yxz1000r-service-guide-final-ver-2