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 CONTENTS
Model Code and Color Chart 1
Specifications 2
Feature Map Chassis 3
Feature Map Engine 6
Feature Map Electrical 7
Vehicle Dimensions 8
Cylinder Head, Cylinder Numbering and Firing Order 9
Valve 11
Camshaft 12
Cam Chain Tensioner, Service, Operation & TDC Marks 13
Air Induction System 22
Cylinder 23
Piston and Connecting Rod 24
Crankshaft and Balancer Weight 26
Engine Pump, Oil Flow and Oil Pressure Switch 28
Fly Wheel and Prop Shaft 31
Clutch and Clutch Hydraulic System 33
Transmission 36
Shifter Change 38
Transmission Lubrication 39
Oil Tank and Engine Oil Maintenance Interval 42
Cooling System 46
Radiator and Water Pump 47
Intake 50
Air Cleaner 51
Throttle Body 55
Injector 56
Exhaust 57
Frame 58
Under Frame Protection 59
Front Fender and Rear Fender 61
Front Grill Carry Bar 63
Door and Door Latch Hinge 64
Drive Shaft 66
Torque Limiter 67
Front Differential 68
Rear Gearcase 69
CVJ Assemblies 70
Gear Select and Adjustment 71
74
76
77
79
81
82
84
85
86
87
88
89
91
93
94
96
100
102
104
105
107
110
111
112
113
115
116
117
118
119
122
124
126
Reverse Lock-Out
Steering
EPS ECU and Diagnostic Wire
Steering Wheel Adjuster
Fuel Tank and Pump
Cab Layout and Driver Foot Pedals
Overhead Protection System
Seat
Driver’s Seat Adjuster
Passenger Handhold
Dashboard Layout
Front A-Arms
Rear A-Arms
Anti-Sway Bars
Front Shocks
Rear Shocks
Suspension Setting Chart
Brakes
Knuckles and Knuckle Bearings
Tires and Tire Pressure Chart
Wheels
Cargo Bed
Sun Top
Meter Assembly
Headlights and Taillight
AC Magneto Generator Assembly, Max Output
Ignition Coils
Rectifier Regulator Assembly
Seat Belt and Parking Brake Buzzer
Center Console, Fuses and Relay Information
ECU Pin-out Maps
Yamaha Diagnostic Tool Information
Genuine Yamaha Accessories

MODEL MODEL CODE COLOR NAME COLOR CODE
YXZ1000R
EPS 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)
YXZ1000R
EPS
YXZ10YPXGL 2HC4
Body: White (PP*)
Rear fenders: Racing Blue (PP*)
Hood: Racing Blue (PP*)
Body: Bluish White Solid 1 (BWS1)
Rear fenders and Hood: Deep Purplish Blue
Solid E (DPBSE)
YXZ10YPXGO 2HC4
Body: 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.
YXZ
10
Y
P
S
X
G
Y, L , O
1ST - 3RD characters = Product group
4th & 5th = engine class, 10 = 1000cc
6th = Y signifies YXZ or YFZ sport models
7th = EPS & 4WD
8th = S signifies Special Edition model
8th = X signifies a standard model
9th = G indicates 2016 model year
Last character = color code, Y = Yellow, L = Blue, O = Orange
1

Model : YXZ1000R
CATEGORY
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:
• Battery
Measurements
• 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, DOHC
80mm x 66.2mm
11.3 : 1
3, Mikuni® 41mm
Regular gas; 86 PON ([R+M]/2) or higher, 91 RON or higher / ethanol content not to exceed 10%
TCI
Electric
Constant mesh, sliding gear - 5 Speed
Non-unit construction (transmission separate from engine assy.) w/ wet multi-disc clutch, shaft with flywheel
Yamaha 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 discs
Dual hydraulic discs / shaft mounted, disc parking brake
MAXXIS® Bighorn™ MU09 / 27 x 9.00R-14, cast aluminum wheels
MAXXIS® Bighorn™ MU10 / 27 x 11.00R-14, cast aluminum wheels
Factory-filled GS U1-H11L, 12 V, 28 AH (10 H)
122.9 in (3121mm) x 64 in (1626mm) x 72.2 in (1834mm)
1510 lb
90.6 in (2300mm)
236 in (6000mm) minimum turning radius
12.9 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 Light
Four 12v12.4/6.2W LED multi-reflector headlights, 12v2.3/0.2W LED taillight w/ brake light
2

FEATURE MAP
Model: 2016 YXZ1000R
27 inch front & rear tire
STD: 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 pivot
double A-arm suspension
piggyback shocks
New Development Item
Current Technology
Front rear brake system
245mm disc brake &
2 piston caliper
Roof support
All new appearance exterior and interior parts
SE: 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

FEATURE MAP
5-speed sequential
manual transmission +
reverse w/
hydraulic clutch
Electric Power Steering
2WD/4WD Diff-lock
Current Technology
Tilt adjusting, soft-grip
steering wheel
9 gal fuel tank
All new appearance exterior and interior parts
SE: painted body, STD: 2 color options
full length TPO plastic skid plates
High–capacity
cooling
system
Analog tachometer, digital
speedometer
& shift position indicator
4

FEATURE MAP
4-cycle 3-cylinder
DOHC 998cc engine
Current Technology
Dry sump external oil
tank
LED tail light
Maximum 300 lb capacity
- plastic cargo bed
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5

FEATURE MAP
Displacement 998cc
Bore x Stroke 80mm x 66.2 mm
Compression Ratio 11.3 : 1
Number of cylinders 3
Cooling System Liquid Cooled
Lubrication Dry Sump
Valve 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-speed
transmission
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
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6

FEATURE MAP
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
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7

DIMENSION MAP
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
F
A
D
E
G
H
B
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8

Component:
At-a-Glance
Service Tip In-depth Info
Cylinder Head
• 3 cylinder DOHC 4 valve cylinder head
• Compression ratio: 11.3:1
IN: 14 degreesEX: 14 degrees
Aluminum head cover
Anti-vibration bolt
Combustion chamber volume
= 24.88cc
• Anti-vibration bolt reduces engine noise
Engine oil filler cap
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9

SERVICE TIP
Cylinder Numbering and Firing Order
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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
31mm26mm
IN
EX
Diameter = 4.5mm
Diameter = 4.5mm
4C8 Lifter
1HX Adjusting
Pad
• Valve Clearance
intake – 0.15~0.22mm
exhaust – 0.21~0.25mm
• Steel intake and exhaust valves and shim under bucket
design deliver proven Yamaha reliability while providing
the best performance
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11

Component:
At-a-Glance
Camshaft
• New design camshafts are used
Valve lift height
IN 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
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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 previous
types
• Refer to the following pages for service information
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13

SERVICE TIP
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.
Reassembly
Step 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)
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14

SERVICE TIP
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.
TIP
Use 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)
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15

SERVICE TIP
Step 5
• Continue to squeeze clip (1) as you compress the tensioner rod (3) further into
the tensioner housing (4) very slowly
• As the tensioner rod (3) is pushed further into the housing, circlip (a) will be
moved into position (e) on the tensioner rod which will lock the rod in place in
the tensioner housing (4)
• Make sure clip (1) is in the groove (c), as outlined in Step 4., and that it is
aligned 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 will
be pushed back into the housing slightly by the timing chain guide, which will
force the circlip (a) out of groove (e) onto the end of the rod which will unlock
the tensioner rod and the spring will then be able to extend the rod outward as
needed during normal operation
Timing Chain Tensioner Inspection & Tensioner Rod Retraction (Continued)
TIP
Make 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.
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16

SERVICE TIP
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 installed
with 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 cable
ties (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 Intake
camshaft sprocket (1) so that the #3 cylinder intake cam lobes (c) are in the position
shown and the sprocket alignment marks (b) are parallel with the cylinder head cover
gasket surface
• Pull the timing chain tight towards the exhaust side and set onto the Exhaust cam
sprocket (2) and place the camshaft into the cylinder head so that the #3 cylinder
exhaust 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)
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17

SERVICE TIP
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 cam
lobes, you can rotate the cam counterclockwise by hand when the camshaft caps are
not installed to double check the alignment of the timing marks (b) with the cylinder
head 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” for
exhaust 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
(Continued)
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18

SERVICE TIP
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) with
the “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 cam
sprockets
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)
(Continued)
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19

SERVICE TIP
Step 9
• Remove the cable ties (1)
• It is very important to only rotate the motor clockwise, if the motor is rotated
counterclockwise with the cylinder head cover removed, even a few degrees, the
timing 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 will
quickly 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 no
oil 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 magneto
cover when cylinder #3 is at TDC on valve overlap (360 degrees after TDC
compression)
• 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 cylinder
head 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 service
manual
(Continued)
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20

SERVICE TIP
AC Magneto Rotor Marks
• The single mark (a) to the left of the “H” mark (b) is TDC for
number 3 cylinder – used for camshaft timing to the crankshaft
• The “H” mark (b) is for dynamic verification of proper ignition
timing and ignition advance, i.e., using a timing light
• The single mark (c) is used to properly align the balancer shaft
counter-weight to enable removal of the water pump assembly
(c)
(a)
(b)
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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 port
Reed valve
Fresh air intake
• The AI system introduces fresh air into the exhaust port
to help complete the combustion process
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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, the
same process used on Yamaha sport bikes
• This is not the same process as Nikasil®
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23

Component:
At-a-Glance
Piston
• 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)
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24

Component:
At-a-Glance
Connecting 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
41mm
20mm
Machined surface
Piston pin oiling holes
Top View
• New steel connecting rods, with a nut-less design to
reduce overall weight
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25

Component:
At-a-Glance
Crankshaft
• Press-method crankshaft is used
• Stroke = 66.2mm
• Press-method manufacturing process is adopted (forging
process without twisting of the metal) to provide the
needed 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 Magneto
thru rotor bolt
Piston cooling jets
Con rod big ends
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26

Component:
At-a-Glance
Balancer Weight
• Newly designed one axis coupling
balancer
• 1:1 gear ratio
Intake
Intake
Balancer weight
Balancer weight
• Single-shaft counter-balancer
• Helps reduce engine vibration - increasing customer
comfort and engine durability
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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 to
all 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 sump
into 2 chambers
• Scavenge pump pulls oil out of the sump and
pumps it into the oil tank
• Oil flows through Oil cooler assy. before going into
tank
• 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
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28

SERVICE TIP
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 with oil filter - 2700cc (2.85 US qt)
1. Oil pump assembly
2. Oil strainer
3. Scavenge pump
4. Oil cooler
5. Feed pump
6. Check valve
7. Relief valve
8. Oil tank
9. Oil filter
10. Oil pressure switch
11. Main gallery
12. Crankshaft
13. Piston coolers
14. AC Magneto rotor bolt
15. Timing chain tensioner
16. Exhaust camshaft
17. Intake camshaft
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29

SERVICE TIP
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.
OPERATION
1. 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 closed
Switch closed = YDT ON*
Oil pressure more than 2 psi, switch open
Switch open = YDT OFF*
* YDT Monitor Mode line number 21
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30

Component:
At-a-Glance
Flywheel
• 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 helps
maintain momentum in the drive line
Balancing holes 19mm
Flywheel
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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
Steel
Plastic
• The U-joints can be removed without unbolting the engine or transmission
• Unbolt the yoke at the engine / flywheel side
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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 the
engine output and deliver reliable power to the
transmission
• Cam damper reduces shock loads in the drive line
Slave cylinder
Clutch rod
Clutch
Input shaft
Input shaft
Cam damper
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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 during
clutch 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 plate
is 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 ± 20cc
• 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 case
correctly
• 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
R
1st
2nd
3rd4th
5th
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

SERVICE TIP
• The oil fill and oil filter screen can be accessed by removing the passenger seat bottom and passenger
side center console cover. The transmission oil drain can be accessed utilizing a cut-out in the center
skid plate (reference page 60)
• The is a wet-clutch design, must use JASO MA certified oil in the transmission to prevent
possible 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 Type
YAMALUBE 10W-40
Oil Capacity
Assembly - 1500 ± 20cc
Return to TOC
40

SERVICE TIP
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 Oil
is recommended,
see next page for weight/type
Checking Oil Level
1. Start engine and warm oil to
140º F (60º C)
2. Let engine idle for at least 10
seconds
3. Unscrew oil tank dipstick wipe off
and reinsert into oil tank (DO
NOT screw dipstick into tank)
4. Check oil level on dipstick
Oil tank
Dipstick
Return to TOC
42

SERVICE TIP
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 baffling
Catch bottle
Heat-exchanger type
oil cooler
Dipstick
• The internal baffling of the oil tank helps prevent oil
starvation for conditions encountered in an off road
environment
Return to TOC
44

SERVICE TIP
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 controlled
cooling system with automatic recovery system
• Engine ECU controls the fan activation, based on
engine 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 Thermo
sensor
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
Impeller
Mechanical seal
Bearing
Drive gear
• The water pump is driven off the balancer shaft
resulting in less moving parts which translates to better
reliability
Return to TOC
48

SERVICE TIP
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 throughout
the entire range, easy to maintain intake system
• Foam filter element MUST be serviced with YAMALUBE Foam Filter Oil
before 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 air
to the engine providing the best possible power while
still maintaining an easy access to primary air cleaner
element
Return to TOCReturn to TOC
Return to TOC
51

Component:
At-a-Glance
• 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

SERVICE TIP
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

SERVICE TIP
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 provides
atmospheric 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 pulsation
damper
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 / CARB
regulations
• Catalyst information; 300 cells/in²
Honeycomb 3-way catalyzer
(83x76.3mm)
Spark arrestor
Return to TOC
57

Component:
At-a-Glance
Frame
• 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 to
support the center console components
ROPS*
Main frame
Sub frame
• *The ROPS system complies with the American
National Standard for Recreational Off-Highway
Vehicles, 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

SERVICE TIP
Engine oil filter drain cutout
Rear gearbox oil drain
Front gearbox oil
drain
Transmission drain
Oil filter galley drainCoolant drain
Return to TOC
60

Component:
At-a-Glance
Front Fender Assy.
• New design front fender
• Polypropylene construction (non-painted models)
• Center hood gives easy access to the radiator, recovery tank, master cylinder reservoirs and
EPS ECU
Center hood
access
Center hood fasteners
Center hood
fastener type
Painted SE models use painted
TPO in place of PP
• 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
(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 front
differential overload protection
• Low maintenance inline rear driveshaft eliminates the
need for U-joints
FWD
Transmission coupler
U-joints with grease fitting
• U-Joint grease fitting is accessed from underneath the vehicle after removing the
skid plates
Top View
Side View
Rear
Gearcase
Front
Differential
Engine input
Rear gearcase coupler
Return to TOC
66

Component:
At-a-Glance
Torque Limiter
• New clutch pack design torque limiter
• 6 friction plates
• 7 steel plates
• Smooth no maintenance front differential overload
protection
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 incorporated
On-Command® servo motor for effortless switching
from 2WD, 4WD or Diff-Lock
Input shaft
Oil drain bolt
1HP-type servo
motor
Oil fill bolt
Oil level
• Oil capacity
Assembly - 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 capacity
Assembly – 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 incorporated
On-Command® servo motor for effortless switching
from 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 CVJ
DOJ = DOJ71A (inside joint)
UJ = VUJ75 (wheel side)
Shaft = Ø 19mm
Rear CVJ
DOJ = 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 the
middle 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
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

SERVICE TIP
Fig. 1
15º
STD position
Shift up position
ARM, SHIFT 2
Fig. 2
Clearance “A”
2mm ± 1mm
Frame
Shift lever
Shifter Adjustment Procedure
1. 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 = 15Nm
4. 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
FWD
Reverse lock-out
cable
lever
Reverse lock-out cable
adjusters
• The reverse lock-out adjustment can be accessed by removing the steering console
cover
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 console
cover
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 soft
grip 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 for
driver 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
147mm
EPS ECU
EPS ECU
• New Mitsubishi® EPS ECU assembly
• Mounted under the center hood access
Return to TOC
77

SERVICE TIP
EPS Diagnostic Wire
EPS Diagnostic Mode
1. Turn main switch ON
2. Disconnect the EPS Diagnostic wire bullet
connector
3. Touch the male terminal to the battery negative
post at least 5 times
4. The EPS system will go into Diagnostic mode
and the EPS light in the multi-function meter will
flash
5. Full details on the EPS fault codes and
diagnostic 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 provides
a 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 steering
wheel 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
Fuel 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
cap
Pipe Assy
Return to TOC
81

Component:
At-a-Glance
• 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 the
floorboard on which the driver rests their left foot
• It is the same height as the clutch pedal, allowing the
driver to move their foot from the ‘dead’ pedal to the
clutch pedal easier
Return to TOC
82

Component:
At-a-Glance
• Automotive-type throttle, brake and clutch pedals are adopted
• Dust cover is utilized
Driver Foot Pedals
• Automotive inspired layout provides the best
ergonomics to control the throttle, brake and clutch
• Dust covers are utilized to help protect vital components
from the outside elements
Driver View
Throttle 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 American
National Standard for Recreational Off-Highway
Vehicles, 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 and
appearance
• Seat shape is tuned for a wide range of riders
• Integrated shoulder bolsters for optimal support,
comfort, and secure feeling
3-point harness
Tuned 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 positions
4 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 handhold
Shaped to provide good
ergonomics 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 the
most favorable balance of ergonomics and function
Ignition switch
Headlight
switch
Diff-lock switch
Center storage
Accessory 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
• Rear shocks are mounted as far out as possible to give
optimum stroke and give the best possible camber to
the rear tires throughout the entire range of travel
F
W
D
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
• Rear shocks are mounted as far out as possible to give
optimum stroke and give the best possible camber to
the 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 to
achieve the desirable amount of body roll to give the
vehicle 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
Tip
Check 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 A
Minimum (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
CompExtension
DampingForce
Front Suspension
Shock 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

SERVICE TIP
Dual Speed
Compression (DSC)
Adjuster
Rebound
Adjuster
2.5” 6061-T6
Aluminum Body
7/8” Induction
Hardened
Steel Shaft
Adjustable
Spring
Preload
2.5” 6061-T6
Aluminum Reservoir
Progressive
Spring
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
• * Dual rate spring (progressive)
Spring installed length (A)
Eye to eye length
CompExtension
DampingForce
Rear Suspension
Shock 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 A
Minimum (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

SERVICE TIP
Shock Name: 2.5” Podium RC2 with BOC
Dual Speed
Compression (DSC)
Adjuster
Rebound
Adjuster
2.5” 6061-T6
Aluminum Body
7/8” Induction
Hardened
Steel Shaft
Adjustable
Spring
Preload
2.5” 6061-T6
Aluminum Reservoir
Progressive
Spring
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 bump
compliance in the upper portion of the stroke, referred to
as 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
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 of
movement of the shaft inside the shock, not vehicle
speed
Return to TOC
99

SERVICE TIP
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:
Standard: 1 ½ turns out from the fully turned in position
Return to TOC
100

SERVICE TIP
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:
Standard: 2 turns out from the fully turned in position
Low speed compression damping setting:
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

SERVICE TIP
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 rear
brake 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 is
difficult 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 Type
Maxxis®
Bighorn™ 2.0
MU09
Maxxis®
Bighorn™ 2.0
MU10
Front
Rear
Return to TOC
105

SERVICE TIP
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 to
differentiate from the competitors
• Optimized offsets help complement the handling to
provide a nimble yet stable feel
• Bolt Pattern
Front - 4 x 110
Rear - 4 x 110
Offset
48mm
Front Rear
Offset
34mm
Rim Size
14 x 6.5
Rim Size
14 x 8.0
Bead Lock RimBead Lock Rim
Standard Rim Standard Rim
Return to TOC
107

Component:
At-a-Glance
Wheels (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

SERVICE TIP
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
F
W
D
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
Meter Assembly
• Analog tachometer
• Digital speedometer
• Digital gear indicator with programmable shift indicator light
Shift Indicator Light
Operating range: more than 9500r/min
User 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 Indicator
Indicator = off 32º~250ºF (0º~121ºC)
Indicator = blue below 32ºF (0ºC)
Indicator = red above 251ºF (122ºC)
Return to TOC
112

Component:
At-a-Glance
• Wattage
low beam: 12V / 6.2W
high beam: 12V / 12.4W
Headlight
• Four eyes headlight design is adopted
• LED headlights are utilized – 2UD-type
• LED headlights provide great illumination with low
power consumption
• LED headlights are considered semi-permanent with an
extremely 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 W
tail light: 12V / 0.5W
Tail Light
• LED tail light is adopted – 1S3-type
• LED tail light - high visibility with low power
consumption
• LED tail lights are considered semi-permanent with an
extremely long service life
Stop = Yellow
Tail light = Blue
Ground = Black
Connector <Taillight Side>
Return to TOC
114

Component:
At-a-Glance
• Stator Output
14V / 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 11
X 1,000 rpm
Amps
• 22 projections on magneto rotor, with ‘gap’ to provide
indexing 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 CR9EB
Gap: 0.028-0.031 in (0.7-0.8mm)
Dust Seal
• Dual fasteners for each coil to help seal out the mud
and dirt encountered on this type of vehicle
Return to TOC
116

Component:
At-a-Glance
84.5mm
70mm
90mm
32mm
Rectifier / Regulator
Rectifier Regulator Assembly
• 1D7-type rectifier regulator is adopted
Return to TOC
117

Component:
At-a-Glance
Buzzer
• 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
Major
electrical
components
Engine air intake
• See next page for details on electrical component location
Return to TOC
119

SERVICE TIP
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® SILICONE
SPRAY PROTECTANT & LUBRICANT
(if the grommets are not lubricated, the posts on the
cover may push them down, out of place when trying
to install the cover)
• Place the cover in the original position and push
the posts into the rubber grommets
2
Return to TOC
120

SERVICE TIP
Battery
GS U1-H11L
ECU
Starter Relay
with15A
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
TERMINAL
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 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34
PIN # CODE NAME PIN # CODE NAME
1 VB Battery Voltage 24 SP Speed Sensor
2 DF12 Differential switch 12 25 DFL2 Differential Lock Rotary Switch 2
3 DFL1 Differential Lock Rotary Switch 1 26
4 WT Water Temperature 27 CT10 YDT Communication
5 PB2 Intake Pressure Sensor 2 28 DL12 Differential Servo Position 2
6 AT Atmospheric Temperature Sensor 29 SB Seat Belt Switch
7 VCC Sensor Power Source 30
8 CRK Crank Position Sensor 31 TP Throttle Position Sensor
9 CANL Can Bus (Low) 32 PB1 Intake Pressure Sensor 1
10 CGND1 Control System Ground 1 33 OPS Oil Pressure Switch
11 DF11 Differential switch 1 34
12 VM Battery voltage Monitor
13
14
15
16 SGND Sensor System Ground
17 CANH Can Bus (High)
18 CGND2 Control System Ground 2
19
20 DL11 Differential Servo Position 1
21 NL Neutral Switch
22 GP Gear Position Sensor
23 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 51
52 53 54 55 56 57 58 59
60 61 62 63 64 65 66 67 68
PIN # CODE NAME PIN # CODE NAME
35 PGND1 Power System Ground 1 47 SBPL Seat Belt Pilot Lamp
36 PGND2 Power System Ground 2 48 BZ Parking Brake Buzzer
37 IJ3 No.3 Cylinder Injector 49 TC Tachometer Drive
38 ISC2 Idle Speed Control Stepping motor 2 50 ST Start Switch
39 ISC3 Idle Speed Control Stepping motor 3 51 AI Air Induction (AI) Relay
40 ISC4 Idle Speed Control Stepping motor 4 52 IG3 Ignition No.3
41 ISC1 Idle Speed Control Stepping motor 1 53
42 54
43 55 MR Main Relay
44 IG1 Ignition No.1 56 RFR Radiator Fan Relay
45 DFR1 Differential Lock Relay 1 57 BRK2 Park Brake Switch
46 DFR2 Differential Lock Relay 2 58 BRK Brake Switch
59 SR Starter Relay Control Output
60 IG2 Ignition No.2
61 IJ2 No.2 Cylinder Injector
62 IJ1 No.1 Cylinder Injector
63
64
65 DL13 Differential Servo Position 3
66 CL Clutch Switch
67
68 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

SERVICE TIP
Yamaha Diagnostic Tool (YDT) – Logging / Monitor Mode Systems
Return to TOC
125

™Check out the full line ofYamaha Genuine Accessories at ShopYamaha.com
NEW! Folding Windshield
The 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 Deflector
The 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
NEW! Center Mount Mirror by Assault Industries
Part 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 Industries
This 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 YXZ1000R
Black*
DBY-ACC56-51-51
White*
DBY-ACC56-51-52
*Available late September 2015
NEW! Desert Front Grab Bar with 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. 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.
Fits ’16 YXZ1000R
2HC-F84L0-V0-00
Available early October
2015

NEW!Trail Front Grab Bar with Winch Plate
This 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).
• 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! Overfenders
This 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 Window
This 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 YXZ1000R
Black
2HC-K750A-V0-00
Available late September 2015
NEW! SpareTireMount
This 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
Black
2HC-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 separately
NOTE:Winch cannot be mounted on the YXZ1000R’s stock front grab bar
Fits ’16 YXZ1000R
SSV-F740C-T0-00
NEW! Winch Wiring Kit
This 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 Cover
Helps 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 Bars
This 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-R0-00
b.15" Light Bar*
2HC-H4104-M0-00
*Available early October
2015
NEW! High Output HALO LED Light Bars
This 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 YXZ1000R
a. 27" Light Bar*
2HC-H4104-T0-00
b. 15" Light Bar*
2HC-H4104-P0-00
2015
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 Kits
These 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-V0-00
b.Flood*
2HC-H4104-L0-00
2015
NEW! Accessory Mount Clamps
These 1.5" clamps allow you to rigidly mount additional accessories (that use 6mm bolts) to the overhead frame
tubes (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 Kit
This 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 System
Yamaha 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 Kit
This 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 unit
NOTE: Dealer installation recommended.
Fits ’16 YXZ1000R
2HC-H1200-V0-00
Coming Soon!
NEW! Rekluse®
Clutch
This 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.
Fits ’16 YXZ1000R
2HC-E63B0-V0-00
NEW! 2nd
Battery Kit
This 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 YXZ1000R
2nd
Battery Kit
2HC-H21B0-V0-00
Available September 2015
2nd
Battery Mount Kit
2HC-H212A-V0-00

SSV-F740C-T0-00
ProVantage 2500 Winch by WARN®
ABA-F740C-V0-00
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 byAntigravity Batteries™ DBY-ACC56-25-02
Micro-Start XP-1 PPS byAntigravity Batteries™ DBY-ACC56-24-57
Micro-Start Mini XP-5 byAntigravity Batteries™ DBY-ACC56-25-01
CurrentYamaha Accessories Also Available for YXZ1000R
NEW! GYTR®
Gauze Air Filter
The 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).
Fits ’16 YXZ1000R
2HC-E41D0-V0-00
Available late October 2015
NEW! GYTR Foam Air Filter
The 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 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.

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