Dokumen - Tips 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 Reverse Lock-Out 74
Specifications 2 Steering 76
Feature Map Chassis 3 EPS ECU and Diagnostic Wire 77
Feature Map Engine 6 Steering Wheel Adjuster 79
Feature Map Electrical 7 Fuel Tank and Pump 81
Vehicle Dimensions 8 Cab Layout and Driver Foot Pedals 82
Cylinder Head, Cylinder Numbering and Firing Order 9 Overhead Protection System 84
Valve 11 Seat 85
Camshaft 12 Driver’s Seat Adjuster 86
Cam Chain Tensioner, Service, Operation & TDC Marks 13 Passenger Handhold 87
Air Induction System 22 Dashboard Layout 88
Cylinder 23 Front A-Arms 89
Piston and Connecting Rod 24 Rear A-Arms 91
Crankshaft and Balancer Weight 26 Anti-Sway Bars 93
Engine Pump, Oil Flow and Oil Pressure Switch 28 Front Shocks 94
Fly Wheel and Prop Shaft 31 Rear Shocks 96
Clutch and Clutch Hydraulic System 33 Suspension Setting Chart 100
Transmission 36 Brakes 102
Shifter Change 38 Knuckles and Knuckle Bearings 104
Transmission Lubrication 39 Tires and Tire Pressure Chart 105
Oil Tank and Engine Oil Maintenance Interval 42 Wheels 107
Cooling System 46 Cargo Bed 110
Radiator and Water Pump 47 Sun Top 111
Intake 50 Meter Assembly 112
Air Cleaner 51 Headlights and Taillight 113
Throttle Body 55 AC Magneto Generator Assembly, Max Output 115
Injector 56 Ignition Coils 116
Exhaust 57 Rectifier Regulator Assembly 117
Frame 58 Seat Belt and Parking Brake Buzzer 118
Under Frame Protection 59 Center Console, Fuses and Relay Information 119
Front Fender and Rear Fender 61 ECU Pin-out Maps 122
Front Grill Carry Bar 63 Yamaha Diagnostic Tool Information 124
Door and Door Latch Hinge 64 Genuine Yamaha Accessories 126
Drive Shaft 66
Torque Limiter 67
Front Differential 68
Rear Gearcase 69
CVJ Assemblies 70
Gear Select and Adjustment 71
Model : 2016 YXZ1000R
MODEL MODEL CODE COLOR NAME COLOR CODE

YXZ1000R Body: Yamaha Yellow (painted)
Body: Yellow Metallic (painted)
YXZ10YPSGY 2HC1 Rear fenders: Yamaha Yellow (painted)
EPS SE Hood: White (PP*)
Hood: Bluish White Solid 1 (BWS1)
Body: White (PP*) Body: Bluish White Solid 1 (BWS1)

YXZ10YPXGL 2HC4 Rear fenders: Racing Blue (PP*) Rear fenders and Hood: Deep Purplish Blue
YXZ1000R Hood: Racing Blue (PP*) Solid E (DPBSE)
EPS Body: Blaze Orange (PP*) Body & rear Fenders: Vivid Yellowish Red Solid 4
YXZ10YPXGO 2HC4 Rear fenders: Blaze Orange (PP*) (VYRS4)
Hood: Gray (PP*) Hood: Dark Gray Metallic E (DNME)
*These parts are polypropylene plastic molded in the color indicated.
YXZ 1ST - 3RD characters = Product group

10 4th & 5th = engine class, 10 = 1000cc
Y 6th = Y signifies YXZ or YFZ sport models
P 7th = EPS & 4WD
S 8th = S signifies Special Edition model
X 8th = X signifies a standard model
G 9th = G indicates 2016 model year
Y, L , O Last character = color code, Y = Yellow, L = Blue, O = Orange
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Model : YXZ1000R
CATEGORY SPECIFICATIONS
Engine
• Type: 998cc, 4-cycle, 3-cylinder, liquid-cooled, DOHC
• Bore x Stroke: 80mm x 66.2mm
• Compression Ratio: 11.3 : 1
• Throttle Body: 3, Mikuni® 41mm
• Fuel Requirement Regular gas; 86 PON ([R+M]/2) or higher, 91 RON or higher / ethanol content not to exceed 10%
• Ignition: TCI
• Starting System: Electric
• Transmission: Constant mesh, sliding gear - 5 Speed
• Drive Type: Non-unit construction (transmission separate from engine assy.) w/ wet multi-disc clutch, shaft with flywheel
• 4WD System: Yamaha On-Command® 3-way locking differential system: 2WD, 4WD and 4WD with Diff-lock
Chassis
• Suspension / Front Independent double wishbone with anti-sway bar, 16.2-in travel, FOX 2.5 Podium® RC2 Shocks®
• Suspension / Rear: Independent double wishbone with anti-sway bar, 17.0-in travel, FOX 2.5 Podium® RC2 Shocks®
• Brakes / Front: Dual hydraulic discs
• Brakes / Rear: Dual hydraulic discs / shaft mounted, disc parking brake
• Tires / Front: MAXXIS® Bighorn™ MU09 / 27 x 9.00R-14, cast aluminum wheels
• Tires / Rear: MAXXIS® Bighorn™ MU10 / 27 x 11.00R-14, cast aluminum wheels
• Battery Factory-filled GS U1-H11L, 12 V, 28 AH (10 H)
Measurements
• L x W x H: 122.9 in (3121mm) x 64 in (1626mm) x 72.2 in (1834mm)
• Wet weight: 1510 lb
• Wheelbase: 90.6 in (2300mm)
• Min. Turning Radius: 236 in (6000mm) minimum turning radius
• Ground Clearance: 12.9 in (330mm)
• Fuel Capacity: 8.98 US gal (34 L)
• Instrumentation: 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
• Lighting: Four 12v12.4/6.2W LED multi-reflector headlights, 12v2.3/0.2W LED taillight w/ brake light
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Model: 2016 YXZ1000R
FEATURE MAP New Development Item
Current Technology
Cut and sew high Sun top
back seats
Slide adjusting
driver seat (no tool)
Color matched rigid bushing pivot

double A-arm suspension Roof support
piggyback shocks
4-beam LED headlights
Color matched rigid bushing pivot

double A-arm suspension w/
piggyback shocks
Front rear brake system

245mm disc brake &
2 piston caliper
27 inch front & rear tire
STD: aluminum cast wheels
All new appearance exterior and interior parts
SE: bead lock wheels
SE: painted body, STD: 2 color options
full length TPO plastic skid plates
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Current Technology
Tilt adjusting, soft-grip

steering wheel
Electric Power Steering

Analog tachometer, digital
speedometer
& shift position indicator
9 gal fuel tank High–capacity

cooling
system
2WD/4WD Diff-lock
5-speed sequential
manual transmission +
reverse w/
All new appearance exterior and interior parts hydraulic clutch
SE: painted body, STD: 2 color options
full length TPO plastic skid plates
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Current Technology
4-cycle 3-cylinder
Maximum 300 lb capacity DOHC 998cc engine
- plastic cargo bed
LED tail light
Dry sump external oil

tank
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FEATURE MAP New 998cc dry sump
3 cylinder engine Cylinder #1 is the forward
Displacement 998cc cylinder, #3 is the rear
Bore x Stroke 80mm x 66.2 mm Dual stage air
cylinder
Compression Ratio 11.3 : 1 cleaner element
Number of cylinders 3
Cooling System Liquid Cooled High capacity exhaust
Lubrication Dry Sump system (catalyst in
Valve Train DOHC AI system muffler)
Manual transmission
Transmission
/5-speed with reverse
Engine weight 117 lb (53 kg)
Transmission weight 87 lb (39.5 kg)
Prop shaft
Cam damper
(input shaft)
5-speed
transmission
w/ reverse
New front
differential
New
Flywheel gearcase
Piston (80mm) /
Torque
66.2mm stroke
limiter Cam damper crankshaft
(middle drive shaft)
External
parking brake
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FEATURE MAP
Center console
battery / fuses / relays
Ignition
Ignition coils
switch
Multi-function
LED Tail
display
light
Headlight /
Diff-lock / Seat belt / parking
switches brake buzzer
EPS ECU
Rectifier /
regulator
Neutral switch
AC magneto
Oil pressure
assembly
switch
Speed
sensor
Starter motor Gear position LED “4-beam”
switch headlights
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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
Ground
E 13 in 330mm
clearance B
F Tread (front) 55 in 1397mm
G Tread (rear) 53 in 1346mm

Maximum
H 15.4 in 390mm
Water Depth
H E
D
F G
A
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At-a-Glance
• 3 cylinder DOHC 4 valve cylinder head
Model: 2016 YXZ1000R • Compression ratio: 11.3:1
Component: Cylinder Head
EX: 14 degrees IN: 14 degrees

Aluminum head cover
Engine oil filler cap
Anti-vibration bolt
Combustion chamber volume
= 24.88cc
Service Tip In-depth Info

• Anti-vibration bolt reduces engine noise
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SERVICE TIP Cylinder Numbering and Firing Order
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At-a-Glance
• Steel intake and exhaust valves are used – 8GL-type
Model: 2016 YXZ1000R • Shim under bucket design
• 7.5mm adjusting pad is used – 1HX-type
Component: Valve
4C8 Lifter
Diameter = 4.5mm
IN
31mm
88.82mm
Diameter = 4.5mm 1HX Adjusting

Pad
EX
26mm
87.92mm

• Valve Clearance • Steel intake and exhaust valves and shim under bucket
intake – 0.15~0.22mm design deliver proven Yamaha reliability while providing
exhaust – 0.21~0.25mm the best performance
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At-a-Glance
• New design camshafts are used
Component: Camshaft
Align 2HC mark with large hole on camshaft flange,

Locating boss also note the I and E stamping locations when the
gears are properly installed
Larger identification
rib
Locating boss
Intake
Smaller
identification rib
Exhaust
Exhaust Intake
Secondary cam identification marks, Exhaust cam has two dots, Intake cam has one

• The camshaft sprockets are the same part number
Valve lift height
• Use the installation information shown above if disassembly or part replacement is required
IN EX
8.6mm 9.9mm
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At-a-Glance
• All new design, self-adjusting hydraulic timing chain tensioner
Model: 2016 YXZ1000R • This tensioner uses oil pressure from the engine as well as a coil spring to
control timing chain tension
Component: Timing Chain Tensioner
Timing chain
Chain guide “UP” arrow

Rod
Tensioner
Chain guide

• 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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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
(5)
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
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SERVICE TIP Timing Chain Tensioner Inspection & Tensioner Rod Retraction (Continued)
Step 3
• Squeeze clip (1) and install spring (2) with plastic spring guide (5), tensioner rod (3)
into the tensioner housing (4)
(5)
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.
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.
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
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SERVICE TIP Timing Chain Tensioner Inspection & Tensioner Rod Retraction (Continued)
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
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.
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
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SERVICE TIP Camshaft and Tensioner Installation & Release Procedure
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
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)
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
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
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)
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(Continued)
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
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(Continued)
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)
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(Continued)
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
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SERVICE TIP AC Magneto Rotor Marks
(b)
• 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 (a)
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)
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At-a-Glance
• Air induction system inlet ports are adopted on the cylinder head
Model: 2016 YXZ1000R • ECU controlled solenoid valve
Component: Air induction system
Solenoid
valve
Fresh air intake
Reed valve
AIS port
Reed valve

• The AI system introduces fresh air into the exhaust port
to help complete the combustion process
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At-a-Glance
• New design aluminum cylinder body
Model: 2016 YXZ1000R • Cylinder bore size: 80mm
• Ceramic coated cylinders - ceramic powder-dispersed, Ni-P composite
Component: Cylinder 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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At-a-Glance
• New design 80mm bore piston is used
Model: 2016 YXZ1000R • Scraper type 2nd ring is used
• Sacrificial “TIN” coating is used for break-in period
Component: Piston
Directional mark
(towards exhaust)
Sectional view of piston ring
Top ring
80mm 2nd ring
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At-a-Glance
• Steel connecting rods are adopted
Model: 2016 YXZ1000R • Connecting rod nuts are eliminated (nut-less design)
• Connecting rod utilizes a thermal refining treatment on the small end
Component: Connecting rod
12 point / 8mm
socket needed for
19mm rod bolts
Machined surface
Top View
118.5mm
Thermal refining
treatment
20mm
41mm
Piston pin oiling holes

• Rod bolts must not be reused • New steel connecting rods, with a nut-less design to
• Tightening method reduce overall weight
1st : 20 Nm (2.0 m·kg, 14 ft·lbf)
2nd: angle-torque to 115-125 degrees
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At-a-Glance
• Press-method crankshaft is used
Model: 2016 YXZ1000R • Stroke = 66.2mm
Component: Crankshaft
Oil to cam chain

tensioner and Con rod big ends
Oil pump drive camshafts Piston cooling jets
sprocket
Oil spray to cool

AC Magneto
thru rotor bolt
Cam chain drive

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

• Press-method manufacturing process is adopted (forging
process without twisting of the metal) to provide the
needed strength to the crankshaft assembly
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At-a-Glance
• Newly designed one axis coupling
Model: 2016 YXZ1000R balancer
• 1:1 gear ratio
Component: Balancer Weight
Balancer weight
Balancer weight
Intake
Intake

• Single-shaft counter-balancer
• Helps reduce engine vibration - increasing customer
comfort and engine durability
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At-a-Glance
• Dry sump oil system
Model: 2016 YXZ1000R • Cartridge oil filter is used – 5GH-type
Component: Engine Oil Pump
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 Scavenge pump
• 1 Feed pump
• Oil flows from the oil tank to the feed pump
Oil sump divider
• Oil is pumped through the oil filter, then into the
engine
• See oil flow diagram on following page
Feed pump
Oil pick-ups

• Oil capacities: • Oil flow is optimized to provide the best lubrication to
Engine fully disassembled - 3400cc (3.7 US qt) all components throughout the entire engine
Oil change - 2500cc (2.64 US qt)
Oil change with oil filter - 2700cc (2.85 US qt)
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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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SERVICE TIP Engine Oil Pressure Switch Operation and Troubleshooting
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.
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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At-a-Glance
• Flywheel to help reduce engine vibration
Component: Flywheel
Balancing holes 19mm
175mm
Flywheel
FWD

• Balancing holes are also used to attach the flywheel holder tool • Flywheel dampens the engine vibration and helps
maintain momentum in the drive line
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At-a-Glance
• U-joint shaft is adopted (reduced noise and vibration)
Model: 2016 YXZ1000R • Engine output support carrier with ball bearings
• 3-piece prop shaft guard is adopted
Component: Engine to Transmission Prop Shaft • Splines are weather-protected by an O-ring
Bearing located in engine

case by pin
Prop shaft
Splined couplers
U-joint
Support Steel
bearings Plastic Prop shaft guard FWD
Flywheel
Oil Tank
Lines
Steel
3 Piece prop shaft
guard

• The U-joints can be removed without unbolting the engine or transmission
• Unbolt the yoke at the engine / flywheel side
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At-a-Glance
• New design multi-plate wet clutch
Model: 2016 YXZ1000R • Input shaft cam damper is adopted
• Gear Ratio → 88/53 = 1.660
Component: Clutch
Clutch rod Cam damper

Input shaft
Clutch
Slave cylinder
Input from engine

Input shaft

• 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
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At-a-Glance
• 11 friction plates
Model: 2016 YXZ1000R • 10 steel plates
• 3 separate judder spring/clutch plate assemblies are adopted
Component: Clutch (continued)
5YU-type friction 2H7-type steel

plates plates
The are 3 separate sets of this judder spring & clutch plate configuration,
which are installed first, and held in place by the retaining wire
2H7 steel plate Judder seat

Retaining wire Judder spring 1PK friction plate
Tab on the
outside plate
is offset when Primary drive
installed gear dampers
Primary drive
gear

• The clutch plates with the judder springs are held in place by a retaining wire • 3 separate judder springs improve the feel during
• The outside friction plate is offset due to the taper of the outer clutch basket clutch engagement
(reduces noise)
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At-a-Glance
• Foot operated clutch system is adopted
Model: 2016 YXZ1000R • Clutch master cylinder and slave cylinder system is adopted
Component: Clutch Hydraulic System
Clutch slave
cylinder
Clutch master
cylinder
Clutch pedal

• Use DOT 4 Brake Fluid
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At-a-Glance
• Manual 5 speed sequential transmission with reverse is adopted
Model: 2016 YXZ1000R • Dual cam dampers are utilized on both the input and output shafts
Component: Transmission
Reverse idler shaft Input shaft cam

Secondary gear & damper
clutch
Main shaft Output shaft cam
damper
Counter shaft
Output to rear
gearcase Output to front
differential

• Oil Capacities:
Assembly - 1500 ± 20cc
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At-a-Glance
• Main shaft / countershaft axles utilize ball bearings
Model: 2016 YXZ1000R • Fixed reverse idler gear shaft is adopted with pressurized oil sprayer
holes to lubricate the transmission gears
Component: Transmission (Continued)
Locating boss
R 2nd 5th
4th 3rd 1st
Reverse idler
shaft Gear Ratio
1st 35/17 = 2.059
Main
Shaft 2nd 34/22 = 1.545
Sprayer 3rd 31/26 = 1.192
Holes Counter
shaft 4th 25/26 = 0.962
5th 25/31 = 0.806
reverse 37/15 = 2.467
middle 41/22 = 1.864
Middle driven
shaft

• 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
37
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At-a-Glance
• Shift claw / shift drum / shift fork design is adopted
Model: 2016 YXZ1000R • Segment / detent design is utilized
Component: Shifter Change
Shift detent
Middle shift Shift drum

fork
Shift claw
Shift shaft
Outside shift forks

• The outside shift forks are the same part & number; can be placed in either position
38
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At-a-Glance
• Dedicated trochoid oil pump is adopted
Model: 2016 YXZ1000R • Oil Pump is driven off the input shaft damper
• Oil filter screen is adopted
Component: Transmission Lubrication
Input shaft
damper
Trochoid oil pump
Oil pump
Oil filter screen

Oil filter screen

• Externally accessible oil filter screen eases maintenance
• Can be removed and cleaned without splitting the transmission cases
39
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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 Oil Type
YAMALUBE 10W-40
• Refer to the Owner’s or Service Manual for oil change interval Oil Capacity
Assembly - 1500 ± 20cc
Remove fastener then pull the oil filter Oil change - 1500cc (1.59 US qt)
screen outward from transmission case
Fastener
Transmission oil
check
Oil filter
screen
Transmission oil
drain
40
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SERVICE TIP Transmission Oil Flow Diagram
Clutch
Input shaft damper axle
Main shaft axle

Oil pump
Countershaft axle
Oil filter screen
Reverse idler gear shaft
Oil pick-up
Transmission sump
41
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At-a-Glance
• External dry sump oil tank is adopted
Model: 2016 YXZ1000R • Catch bottle is utilized
Component: Oil Tank
Total Oil Capacity 3400cc
With oil filter

2700cc
replacement
Without oil filter
2500cc
replacement*
YAMALUBE Oil
is recommended,
see next page for weight/type
Oil tank
drain Dipstick Checking Oil Level
1. Start engine and warm oil to
Oil tank 140º F (60º C)
lines 2. Let engine idle for at least 10
seconds
Oil tank 3. Unscrew oil tank dipstick wipe off
and reinsert into oil tank (DO
NOT screw dipstick into tank)
FWD 4. Check oil level on dipstick

• When overhauling the engine, pour; • High efficiency, low maintenance oil cooling system
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
42
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SERVICE TIP Engine and Driveline Lubrication Charts
43
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At-a-Glance
• Oil tank has internal baffling
Model: 2016 YXZ1000R • Oil is cooled by the engine coolant via a heat-exchanger type oil cooler
Component: Oil Tank (Continued)
Catch bottle
Oil tank baffling
Dipstick
Heat-exchanger type
oil cooler

• The internal baffling of the oil tank helps prevent oil
starvation for conditions encountered in an off road
environment
44
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SERVICE TIP To access the oil tank dip stick the cargo bed cover must be removed
Oil tank dip stick
Remove the 5 cargo bed ¼ turn quick

fasteners then remove the cover
¼ Turn Quick Fasteners

45
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At-a-Glance
• New radiator and fan assembly is adopted
Model: 2016 YXZ1000R • Thermostat utilized – 5LP-type
• Thermo sensor is utilized – 5YP-type
Component: Cooling System
Recovery tank
Thermostat Assembly
5LP Thermostat
5YP Thermo 5LP

sensor Thermostat
Coolant drain
Coolant hoses
Radiator and fan
assy.
FWD

Total coolant capacity 3750cc
• High efficiency, low maintenance, thermostat controlled
cooling system with automatic recovery system
Total coolant recovery tank 250-310cc • Engine ECU controls the fan activation, based on
50/50 distilled water and anti-freeze mix engine coolant temperature
• With circuit breaker protection
46
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At-a-Glance
• New design aluminum radiator/fan assembly
Model: 2016 YXZ1000R • Manufactured by T.RAD® North America, Inc.
Component: Radiator
394.2mm
28mm
400mm

• Radiator fill is located underneath the center hood access
• Radiator capacity: 47.4kw
47
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At-a-Glance
• New design Mikuni® water pump
Model: 2016 YXZ1000R • Water pump is driven off the balancer shaft
• Mechanical seal with integrated weep hole
Component: Water Pump
5LP-type Water pump

Thermostat
Balancer shaft
Water pump Drive gear Impeller

Mechanical seal
Weep hole
drain tube
Bearing

• Working RPM - 6700rpm • The water pump is driven off the balancer shaft
• Working pressure – 21.7 psi (150kPa) resulting in less moving parts which translates to better
• Water delivery - 47.5 gal/min (180 L/min) reliability
48
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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
49
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At-a-Glance
• High mounted intake
Model: 2016 YXZ1000R • Intake for the air box is located inside the center console
Component: Intake
Top View
Side View
FWD

• Foam filter element MUST be serviced with YAMALUBE Foam Filter Oil • High volume for increased power output throughout
before delivery the entire range, easy to maintain intake system
• Air filter element should be checked more often in dusty / wet conditions
50
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At-a-Glance
• New design air filter case
Model: 2016 YXZ1000R • Easy access layout for primary element
Component: Air Cleaner
Primary air cleaner element Wet paper type Secondary air cleaner element
(viscous)
Oiled urethane
foam
Return to TOC
Center torque cam

type
(tool-less)

Primary Air Cleaner • Dual air filters elements provide optimal filtration of air
• Clean and replace if necessary every 200-400 mi (300-600 km) to the engine providing the best possible power while
Secondary Air Cleaner still maintaining an easy access to primary air cleaner
• Replace every 1200-3000 mi (2000-5000 km) element
NOTE: Service both the Primary and Secondary air cleaners more often in wet or dusty conditions.
51
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At-a-Glance
• Easy access to primary foam air cleaner element under cargo bed cover
Model: 2016 YXZ1000R • Tools are not required to service primary foam air cleaner element
• Viscous paper air cleaner can be accessed from the right rear wheel well
Component: Air Cleaner (continued)
Viscous paper air

Foam air filter
filter
Air temp Air box drain

sensor tube

• Continued on following pages
52
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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
¼ turn quick fasteners
Remove the foam air cleaner element by rotating the

air cleaner case cap counter clockwise
53
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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
Air box fastener
Remove the 11 air box

lid fasteners then
remove the cover
Remove the 3 oil tank

cover fasteners then
remove the cover
54
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At-a-Glance
• Triple 41mm throttle bodies are utilized
Model: 2016 YXZ1000R • Idle Speed Controller (ISC) stepper motor is adopted
• Dual pressure sensors are utilized eliminating the need for a cylinder
Component: Throttle Body identification sensor
Sensor #2 Sensor #1 1WS-type pressure

5VK-type pulsation sensors New injectors
ISC
damper
Fuel inlet
Throttle stop screw

ISC - fresh air inlet
3B4-type throttle 2HC1 00
position sensor
Model code marking

• Sensor #2 connected to cylinder #1 only – performs cylinder ID function and provides
atmospheric pressure information
• Sensor #1 connected to all cylinders
55
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At-a-Glance
• New Mitsubishi® 4-hole injector is adopted
Component: Injector
4-hole Injector
56
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At-a-Glance
• New, stainless steel construction exhaust system
Model: 2016 YXZ1000R • Honeycomb catalyzer integrated into muffler
• Removable spark arrestor
Component: Exhaust
Spark arrestor
Honeycomb 3-way catalyzer

(83x76.3mm)

• High volume exhaust system, meeting EPA / CARB
regulations
• Catalyst information; 300 cells/in²
57
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At-a-Glance
• New design frame is utilized
Model: 2016 YXZ1000R • Sub frame section over transmission is adopted
• Bolt on engine bracket
Component: Frame • New design roll-over protection structure (ROPS)*
ROPS*
Main frame
Sub frame
Bolt-on engine
bracket
(color matched)

• Sub frame is removable to help aid in the removal of the transmission, shifter rigidity and to • *The ROPS system complies with the American
support the center console components National Standard for Recreational Off-Highway
Vehicles, ANSI/ROHVA-1-2011 Standard
58
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At-a-Glance
• 3-piece TPO removable middle skid plates
Model: 2016 YXZ1000R • TPO side guards are adopted
• Rear Guard TPO is 6mm in thickness
Component: Under Frame Protection • All other guards are 4mm in thickness
Side guard
Rear guard
Front guard
Side guard Middle guard
FWD

• Full under frame protection with easy access to service items • TPO = thermoplastic olefin
• See next page for details • TPO is a good material for impact resistance, flexibility
and wear
• The vehicle will easily glide over most obstacles
encountered on the trail
59
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SERVICE TIP Engine oil filter drain cutout
Rear gearbox oil drain
Front gearbox oil

drain
Coolant drain Oil filter galley drain
Transmission drain
60
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At-a-Glance
• New design front fender
Model: 2016 YXZ1000R • Polypropylene construction (non-painted models)
Component: Front Fender Assy.
Center hood Center hood fasteners

access
Center hood
fastener type
Painted SE models use painted

TPO in place of PP

• Center hood gives easy access to the radiator, recovery tank, master cylinder reservoirs and • TPO = thermoplastic olefin
EPS ECU • PP = polypropylene
61
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At-a-Glance
• New design rear fender
Model: 2016 YXZ1000R • Polypropylene construction (non-painted models)
Component: Rear Fenders
Painted SE models use painted

Right rear TPO in place of PP
fender panel Cargo bed
Left rear fender

panel

• TPO = thermoplastic olefin
(also known as thermoplastic polyolefin)
• PP = polypropylene
62
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At-a-Glance
• New design front grill
Model: 2016 YXZ1000R • New design front carry bar
• Complement the “four eyes” LED headlight layout
Component: Front Grill and Carry Bar
Front carry bar
Grill
63
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At-a-Glance
• Blow-molded door panel
Model: 2016 YXZ1000R • Color matched outer cover door panels are utilized
Component: Door
Inside View
Outside View
Top View
Mark is placed here to indicate door

handle position from the outside
64
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At-a-Glance
• 2-stage automotive-style latch is utilized
Model: 2016 YXZ1000R • Door handle mechanism is protected inside the door panel
• Coil style door return springs are utilized
Component: Door Latch and Hinge
2-stage latch
Hinge mounting
fasteners
Return spring
Door handle
rod
Striker bolted to
frame

• Smooth durable door latch system with less effort
65
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At-a-Glance
• Single piece front driveshaft with U-joint fittings
Model: 2016 YXZ1000R • Single piece inline rear driveshaft with coupler fittings
Component: Drive Shaft
Top View
FWD
Engine input
Rear gearcase coupler

U-joints with grease fitting
Front Rear
Differential Side View Gearcase
Transmission coupler

• U-Joint grease fitting is accessed from underneath the vehicle after removing the • Smooth, easy to service front driveshaft with front
skid plates differential overload protection
• Low maintenance inline rear driveshaft eliminates the
need for U-joints
66
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At-a-Glance
• New clutch pack design torque limiter
Model: 2016 YXZ1000R • 6 friction plates
• 7 steel plates
Component: Torque Limiter
FWD
Snap Ring Spring Inner Splined Case

Ring
Friction Plate
Output Shaft Plate Outer Splined End Pack
Pack
Steel Plate

• Smooth no maintenance front differential overload
• Slip Torque – 280~390 Nm
protection
67
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At-a-Glance
• New front differential
Model: 2016 YXZ1000R • 1HP-type servo motor is utilized
• Gear ratio = (9/33)
Component: Front Differential
Input shaft Oil fill bolt
1HP-type servo
motor Oil level
Removable Oil drain bolt

bracket

• Oil capacity • Proven Yamaha technology with incorporated
Assembly - 200cc (±20cc) On-Command® servo motor for effortless switching
Oil exchange - 180cc (±20cc) from 2WD, 4WD or Diff-Lock
• SAE 80 API GL-4 Hypoid gear oil is used
68
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At-a-Glance
• New rear gearcase
Model: 2016 YXZ1000R • Gear ratio = (9/33)
• External parking brake is adopted
Component: Rear Gearcase • Ring gear lock mechanism is integrated into gearcase design
External parking brake Vent

Removable Oil fill bolt
caliper mount
bracket
Ring gear lock

External parking mechanism
brake disc mount
Oil level
Oil drain bolt

• Oil capacity • Proven Yamaha technology with incorporated
Assembly – 520cc (±30 cc) On-Command® servo motor for effortless switching
Oil exchange - 470 cc (±20cc) from 2WD, 4WD or Diff-Lock
• SAE 80 API GL-4 Hypoid gear oil is used
69
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At-a-Glance
• New front and rear constant-velocity joint (CVJ) assemblies
Model: 2016 YXZ1000R • 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
Component: CVJ Assemblies CVJ
Rear CVJ
DOJ = DOJ87L (inside joint)
UJ = EBJ82M (wheel side)
Shaft = Ø 21.2mm
Front CVJ
DOJ = DOJ71A (inside joint)
UJ = VUJ75 (wheel side)
Shaft = Ø 19mm

• DOJ = double offset joint (plunging joint type)
• UJ = undercut free joint (fixed joint type)
• PEEST = Polyesterester
• CR = Chloroprene Rubber (Neoprene)
70
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At-a-Glance
• Located on middle console
Model: 2016 YXZ1000R • Shift rod is adopted
Component: Gear Select
Center console mounted

shifter Center console mounted
shifter
Linkage rod
FWD
Engine shift
mechanism

• The shifter rod adjustment can be accessed by removing the center console cover • Best ergonomics for the driver being located on the
• Adjustment procedure on following page middle console while still being easy to adjust
71
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At-a-Glance
• Manual 5 speed sequential transmission with reverse is adopted
Component: Sequential Shift Pattern

• The reverse lock-out lever must be pulled to allow shifting into reverse
72
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SERVICE TIP
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.
Fig. 1 Fig. 2
Shift lever
15º
STD position
Shift up position
Clearance “A” Frame
2mm ± 1mm
ARM, SHIFT 2
73
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At-a-Glance
• Lever operated reverse lock-out is located on the steering console
Model: 2016 YXZ1000R • Reverse lock-out cable is utilized
Component: Reverse Lock-out
Reverse lock-out cable

adjusters
Center console mounted

lever
FWD
Reverse lock-out
cable

• The reverse lock-out adjustment can be accessed by removing the steering console
cover
74
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At-a-Glance
• Reverse lock out stopper is located on the shift drum
Component: Reverse Lock-out (continued)
Reverse lock-out Reverse lock-out cable

cable
Shift drum
Reverse lock-out
stopper

• The reverse lock-out adjustment can be accessed by removing the steering console
cover
75
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At-a-Glance
• New soft grip steering wheel with steel armature, PP substrate and soft
Model: 2016 YXZ1000R grip over-mold
• New rack and pinion steering assembly is utilized
Component: Steering • New EPS motor assembly is located on the steering column
Rack and Pinion steering assembly

EPS motor
assembly
Tie rod end
Over-mold
(black)
Steering shaft
assembly
Steering
assembly
Armature PP substrate
(orange) (green)
Rack end set

• Rack End Set is available as a separate service part • Comfortable steering wheel and optimal position for
driver to reduce effort and fatigue
• PP = Polypropylene
76
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At-a-Glance
• New Mitsubishi® EPS ECU assembly
Model: 2016 YXZ1000R • Mounted under the center hood access
Component: EPS ECU
110mm
147mm
EPS ECU
77
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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)
78
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At-a-Glance
• New quick adjust, gas-charged steering wheel height adjuster is adopted
Component: Steering Wheel Adjuster
Fully raised Fully lowered
Steering wheel pivot

bracket
Gas-charged steering
wheel adjuster

• The new quick adjust steering wheel adjuster provides
a wide range of adjustment for a variety of drivers
79
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At-a-Glance
• Pull the release lever (towards the driver) and hold, move the steering
Model: 2016 YXZ1000R wheel to the desired position then release the lever
• The steering wheel is adjustable to any position within the range of travel -
Component: Steering Wheel Adjuster (Continued) 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.
80
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At-a-Glance
• New fuel tank located under passenger seat
Model: 2016 YXZ1000R • B16-type fuel pump is utilized
• 28P-type Pipe Assy. is used
Component: Fuel Tank and Pump • Multi-layer design is adopted to eliminate the need for fluorination
1XD-type fuel
Pipe Assy
cap
Fuel pump

• Fuel Tank Capacity:
9.0 US Gal (34 L)
81
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At-a-Glance
• Dedicated closed-in floorboards for both driver and passenger
Model: 2016 YXZ1000R • Automotive inspired cockpit layout
• Textured, angled floorboard with heel stop for the driver
Component: Cab Layout
Center storage
Heel stop 2 cup

Adjustable holders
Glove box
steering wheel
Clutch pedal
Textured
floorboard
Driver ‘dead’ Passenger

pedal ‘dead’ pedal
Driver floorboard Passenger floorboard

Brake pedal
Center mounted
shifter/switches/parking brake
lever/seat belt & helmet
Throttle pedal indicator

• 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
82
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At-a-Glance
• Automotive-type throttle, brake and clutch pedals are adopted
Model: 2016 YXZ1000R • Dust cover is utilized
Component: Driver Foot Pedals
Brake switch
Clutch switch
Rubber dust cover
Clutch pedal
PP dust cover
Brake pedal
Driver View
Throttle pedal

• 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
83
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At-a-Glance
• Roll-over protection structure (ROPS) system*
Model: 2016 YXZ1000R • 2 mounts for whip flags
Component: Overhead Protection System
Sun top support
Rear View
Side member
Cross member
Whip flag
mounts
Side member

• The roll-over protection structure and sun top are installed by the dealer • *The ROPS system complies with the American
National Standard for Recreational Off-Highway
Vehicles, ANSI/ROHVA-1-2011 Standard
84
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At-a-Glance
• Driver seat location is adjustable – forward & back 3.5 in (90mm)
Model: 2016 YXZ1000R • 3-point seat belt for both driver and passenger
• Integrated shoulder bolsters
Component: Seat
3-point harness Shoulder bolsters

‘Cut and sew’ style are adopted Tuned seat back
seat
Bottom seat
cushion is
removed with
same steps as
1XP

• 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
85
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At-a-Glance
• New quick adjust driver’s seat is adopted
Model: 2016 YXZ1000R • 8 positions possible
• Forward / back adjustment range – 3.5 inches (90mm)
Component: Driver’s Seat Adjuster
Seat adjustment
notches
New quick
adjust seat
adjuster
Seat adjust lever

• To adjust – pull up on the seat adjuster lever
• Move to the desired position Never adjust the seat position while operating the
vehicle, otherwise the seat may suddenly change
position, which may lead to an accident.
86
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At-a-Glance
• Non-removable passenger handhold is adjustable with 3 positions
Model: 2016 YXZ1000R 4 inch (100mm) total adjustment range
• Adjustment method is the same as 1XP-type
Component: Passenger Handhold
Shaped to provide good

3-position handhold
ergonomics for the passenger

• 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
87
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At-a-Glance
• Forward mounted meter assembly
Model: 2016 YXZ1000R • Automotive rotary style Diff-lock/Headlight/Ignition switches
• Center mounted accessory outlet (12V/10A/120W max)
Component: Dashboard Layout
Accessory outlet Latching glove box

Center storage
Meter assembly
Ignition switch
Parking brake
Shift lever
Headlight Helmet / seat belt

switch light
Diff-lock switch

• Control, display and storage items are placed for the
most favorable balance of ergonomics and function
88
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At-a-Glance
• New design color matched A-arms
Model: 2016 YXZ1000R • Bump steer = 7.2mm
• Suspension ratio is optimized
Component: Front A-arms • Plastic CV guards
Front CV Guard
New A-arm
Design
Front CV Guard Extend 1G’ Compress

• Always inspect CV boots for cracks or tears as part of the pre-ride inspection • Optimized caster, bump steer and Ackerman steering
geometry throughout the travel and steering angle
89
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At-a-Glance
• Caster = 6.80º
Model: 2016 YXZ1000R • Trail = 1.33 in (33.7mm)
Component: Front Suspension
Side View

• 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
90
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At-a-Glance
• New design – super wide-span A-arm
Model: 2016 YXZ1000R • Color matched A-arms
• New spherical bearings are used on the lower A-arms
Component: Rear A-arms • Suspension ratio is optimized
Rubber boot
Spherical Circlip
bearing
New A-arm F
Design W
D

• Always inspect CV boots for cracks or tears as part of the pre-ride inspection • 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
91
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At-a-Glance
• New design, color matched long A-arms
Model: 2016 YXZ1000R • New spherical bearings are used on the lower A-arms
• Suspension ratio is optimized
Component: Rear A-arms (Continued)

• 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
92
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At-a-Glance
• New sway bar for the front suspension
Model: 2016 YXZ1000R • Sway bar is adopted for the rear suspension
Component: Anti-sway Bars
Front sway bar
Rear sway bar Sway bar bushing
Self-adhesive reflective heat

shielding is used on top of
the left rear sway bar mount
(due to exhaust location) Tip
Check for wear in this area

• Check sway bar bushings on a regular basis for wear and replace as needed • 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
93
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At-a-Glance
• New long travel FOX® Podium® RC2 shocks are adopted
Model: 2016 YXZ1000R • Adjustable High/Low speed compression damping
• Adjustable rebound damping
Component: FOX® Shocks - Front • Adjustable spring preload
Eye to eye length
Spring installed
Extension
length (A)
Damping Force
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)
Comp
Piston Outside Diameter 2.3 in (57.2mm)

• Spring preload setting: distance A • Preload adjusting nut tightening torque: • * Dual rate spring (progressive)
Minimum (soft): 428.2mm (16.86 in) Locknut:
Standard: 415.5mm (16.36 in) 41 Nm (4.1 m·kg, 30 ft··lb)
Maximum (hard): 402.8mm (15.86 in)
94
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SERVICE TIP Note: Aluminum construction allows for reduced weight and improved heat
dissipation
Dual Speed
Compression (DSC) 2.5” 6061-T6
Adjuster Aluminum Reservoir
7/8” Induction
Hardened Rebound
Steel Shaft Adjuster
DX Bearings
2.5” 6061-T6 Adjustable (both mounts)
Aluminum Body Spring Progressive
Preload Spring
95
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At-a-Glance
• New long travel FOX® Podium® RC2 shocks are adopted
Model: 2016 YXZ1000R • Adjustable High/Low speed compression
• Adjustable rebound damping
Component: FOX® Shocks - Rear • Adjustable spring preload
Eye to eye length
Spherical
bearing
Spherical
bearing
Extension
Spring installed length (A)

Damping Force
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)
Comp
Piston Outside Diameter 2.3 in (57.2mm)

• Spring preload setting: distance A • Preload adjusting nut tightening torque: • * Dual rate spring (progressive)
Minimum (soft): 496.8mm (19.56 in) Locknut:
Standard: 484.1mm (19.06 in) 41 Nm (4.1 m·kg, 30 ft·lb)
Maximum (hard): 471.4mm (18.56 in)
96
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SERVICE TIP Shock Name: 2.5” Podium RC2 with BOC Note: Aluminum construction allows for reduced weight and improved
heat dissipation
Dual Speed
Compression (DSC) 2.5” 6061-T6
Adjuster Aluminum Reservoir
7/8” Induction
Hardened Rebound
Steel Shaft Adjuster
Teflon Lined
Bottom Out 2.5” 6061-T6 Adjustable COM 10
Cup (BOC) Aluminum Body Spring Progressive Spherical
Position Preload Spring Bearings
Sensitive (both mounts)
Damping
Technology
97
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At-a-Glance
• FOX® Bottom-Out Control (BOC) is adopted on the rear shocks
Component: Rear Shocks - Rear (continued)
Ride Zone
• Oil will bypass the secondary piston
• The primary piston provides the damping for the
majority of the stroke
Secondary Primary
BOC shim BOC
Piston Piston
stack
BOC Zone (approx. final 25% of travel)

• The secondary piston enters the bottom-out cup
• The primary and secondary piston provides the
damping force

• 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
98
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At-a-Glance
• Adjustable High/Low speed compression damping
Model: 2016 YXZ1000R • Adjustable rebound damping
• Adjustable spring preload
Component: FOX® Shocks – Front & Rear
High speed
(hex head)
& Low speed
(screw driver slot) Spring preload
compression adjustment
damping adjusters
Rebound damping
adjuster

• High speed and Low speed refers to the rate of
movement of the shaft inside the shock, not vehicle
speed
99
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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
100
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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
101
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At-a-Glance
• Nissin® 17.5 x 18mm dual-chamber type master cylinder
Model: 2016 YXZ1000R • New front Nissin® dual 32mm piston calipers
• New rear Nissin® dual 27mm piston calipers
Component: Brakes (Front and Rear) • 9.6 inch (245mm) diameter rotors are adopted
Front brake
caliper
Master cylinder
Brake pipe
junction
Frame Rear brake
caliper

• Use DOT 4 Brake Fluid
102
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SERVICE TIP Dual Master Cylinder
FWD
To both front
brake calipers
To both rear
brake calipers
Rear brake
Front brake
pressure
pressure
chamber
chamber
Secondary piston Primary piston
• 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
103
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At-a-Glance
• New design knuckles are adopted
Model: 2016 YXZ1000R • New style wheel bearings are utilized
Component: Knuckles
Rear Knuckle Front Knuckle
Grease fitting
Grease fitting
104
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At-a-Glance
• Yamaha exclusive 27-inch Maxxis® Bighorn™ 2.0 tires
Model: 2016 YXZ1000R • Radial construction
Component: Tires
Front
Front Rear
Tire Size 27x9.00R14 27x11.00R14
Ply Rating 6
Air Pressure See next page
Maxxis® Maxxis®
Tire Type Bighorn™ 2.0 Bighorn™ 2.0
MU09 MU10
Rear

• Always set tire pressure to recommended spec and inspect for cracks or punctures during • 27-inch tires provide excellent ground clearance,
“Pre-Ride Inspection” traction, durability, comfort and steering precision
105
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SERVICE TIP Vehicle Loading and Tire Air Pressure Chart
106
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At-a-Glance
• New cast aluminum wheels (all models / bead lock rims shown)
Model: 2016 YXZ1000R • SE and 60th anniversary models adopt bead lock rims
Component: Wheels
Bead Lock Rim Front Bead Lock Rim Rear
Rim Size Rim Size

Standard Rim Standard Rim
14 x 6.5 14 x 8.0
Offset Offset
34mm 48mm

• Bolt Pattern • Cast aluminum rims provide an aggressive look to
Front - 4 x 110 differentiate from the competitors
Rear - 4 x 110 • Optimized offsets help complement the handling to
provide a nimble yet stable feel
107
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At-a-Glance
• New 14 inch bead lock wheels are adopted (60th and SE models only)
Model: 2016 YXZ1000R • Lock plate is secured by 15 fasteners
Component: Wheels (Bead Lock)
Tire Bead Channel

Cast Aluminum
Cast Aluminum Lock Plate
M6 Fasteners Rim
Rim Lock Plate

• The M6 fasteners will need to be re-torqued as a periodic maintenance item
108
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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)
109
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At-a-Glance
• Polypropylene construction
Model: 2016 YXZ1000R • Fixed position (bed does not tilt) with 300 lb cargo capacity
• Storage compartment
Component: Cargo Bed • 4 steel tie down points
Steel tie down points

Storage compartment Cargo bed cover
Storage compartment
F
Cargo Bed Capacity 300 lb / 136 kg W
D
Total Vehicle
728 lb / 330 kg
Capacity

• Strong, light and durable construction
• 4 steel tie down points welded to the frame for securing
gear in rough terrain
110
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At-a-Glance
• Polypropylene construction
Model: 2016 YXZ1000R • Standard component on all models
Component: Sun Top
Bottom View
Sun top
FWD support

• Installed by dealer
• Use a square tipped driver to install the sun top
bracket screws
111
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At-a-Glance
• Analog tachometer
Model: 2016 YXZ1000R • Digital speedometer
• Digital gear indicator with programmable shift indicator light
Component: Meter Assembly
Shift indicator light Parking brake Shift Indicator Light

Tachometer EPS indicator
Operating range: more than 9500r/min
red zone indicator User adjustable setting: turn on rpm
Reverse/Neutral
10,500 ~12,000 Diff-Lock indicator Indicators
turn off rpm
Modes: ON, OFF or BLINK

Check Engine
Light
Engine coolant
temperature indicator
SELECT button
MODE button
Connector <Meter Side>

RESET button
1 BATT+ 5 CAN-LO
Gear position Odometer/Trip Clock/Hour/Voltage 2 IGN+ 6 CAN-HI

indicator N,R,1~5 Speedometer 3 GND 7 FUEL
KMH or MPH Fuel meter
4 EPS 8

• Engine Coolant Temperature Indicator
Indicator = off 32º~250ºF (0º~121ºC)
Indicator = blue below 32ºF (0ºC)
Indicator = red above 251ºF (122ºC)
112
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At-a-Glance
• Four eyes headlight design is adopted
Model: 2016 YXZ1000R • LED headlights are utilized – 2UD-type
Component: Headlight
Low beam (upper LED Chip

High beam
(upper & lower side) side only)
HI beam = Yellow
Low beam = Green
Ground = Black
Connector <Headlight Side>

• Wattage • LED headlights provide great illumination with low
low beam: 12V / 6.2W power consumption
high beam: 12V / 12.4W • LED headlights are considered semi-permanent with an
extremely long service life
113
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At-a-Glance
• LED tail light is adopted – 1S3-type
Component: Tail Light
Stop = Yellow
Tail light = Blue
Ground = Black
Connector <Taillight Side>

• LED tail light - high visibility with low power
• Wattage:
consumption
brake light: 12V / 3.9 W
• LED tail lights are considered semi-permanent with an
tail light: 12V / 0.5W extremely long service life
114
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At-a-Glance
• Mitsubishi® magneto assembly
Model: 2016 YXZ1000R • Mounted directly at the rear of the engine
Component: AC Magneto Assembly
Crankshaft
40 Position Sensor
35
30
25
20
Amps
15
10
0
1 2 3 4 5 6 7 8 9 10 11
AC Magneto
X 1,000 rpm
Reluctors

• Stator Output • 22 projections on magneto rotor, with ‘gap’ to provide
14V / 33.7A / 472W @ 5000 rpm indexing function to determine exact piston position
115
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At-a-Glance
• New Mitsubishi® ignition coils
Model: 2016 YXZ1000R • Each coil is mounted using 2 fasteners
Component: Ignition Coil
Ignition Coil
Dust Seal

• Spark Plug: NGK CR9EB • Dual fasteners for each coil to help seal out the mud
Gap: 0.028-0.031 in (0.7-0.8mm) and dirt encountered on this type of vehicle
116
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At-a-Glance
• 1D7-type rectifier regulator is adopted
Component: Rectifier Regulator Assembly
84.5mm
90mm
70mm
Rectifier / Regulator
32mm
117
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At-a-Glance
• 2MB-type buzzer is adopted
Model: 2016 YXZ1000R • Buzzer will sound if driver seat belt is not latched or parking brake is
engaged and a signal is received from speed sensor
Component: Buzzer
Speed sensor Seat belt switch
Buzzer located on
steering column
ECU
Meter assembly
Buzzer
Batt.
Parking brake switch

• Buzzer is located on the steering column
118
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At-a-Glance
• Major electrical components are located under the center console cover
Component: Center Console (Electrical Components Access)
Engine air intake
Major
electrical
components
Remove the center

console cover

• See next page for details on electrical component location
119
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SERVICE TIP Removing & Reinstalling Center Console - Rubber Grommets
REMOVING REINSTALLING
• Remove the center console cover (1) by pulling it up as • Make sure the two rubber grommets (2) are in
shown place and lubricate with YAMALUBE® SILICONE
SPRAY PROTECTANT & LUBRICANT
• After removing account for the two rubber grommets (2),
(if the grommets are not lubricated, the posts on the
they may come off with the cover, or fall out of place
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
120
SERVICE TIP
Fuse Box w/ Fuse Box
Auxiliary DC jack
fuse (Terminal)
40A EPS Fuse
Starter Relay
40A Main Fuse with15A
TERMINAL
FI fuse
10A
Lean Angle Sensor
Battery
GS U1-H11L
8DM Relays
Hi Beam Headlight Relay Starter Relay
Low Beam Headlight
ECU Relay
Fan Relay
Fuel System Relay
4WD Relay 1
Load Control Relay
4WD Relay 2 (power into fuse box)
15A FI fuse 15A Spare fuse
121
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At-a-Glance
• New Mitsubishi® ECU is adopted
Model: 2016 YXZ1000R • CAN Bus communication is utilized
• YDT is adopted
Component: ECU
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
1 2 3 4 5 6 7 8 9
21 NL Neutral Switch
10 11 12 13 14 15 16 17 22 GP Gear Position Sensor
18 19 20 21 22 23 24 25 23 LA Lean Angle Sensor
26 27 28 29 30 31 32 33 34

• 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
122
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At-a-Glance
• New Mitsubishi® ECU is adopted
Model: 2016 YXZ1000R • CAN Bus communication is utilized
• YDT is adopted
Component: ECU
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
35 36 37 38 39 40 41 42 43
67
44 45 46 47 48 49 50 51 68 BAT Battery Voltage
52 53 54 55 56 57 58 59
60 61 62 63 64 65 66 67 68

• 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
123
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At-a-Glance
• Yamaha Diagnostic Tool (YDT) is adopted
Model: 2016 YXZ1000R • Diagnostic service tool connector is located under the center console cover
Component: Yamaha Diagnostic Tool (YDT)

• B/W = ground • K-line communication is utilized
• R/W = battery voltage (hot, before main switch) • FFD is not adopted
• Y/W = data line
• Diag Mode in not available through multi-function meter assy.
124
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SERVICE TIP Yamaha Diagnostic Tool (YDT) – Logging / Monitor Mode Systems
125
ACCESSORIES ™
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
Check out the full line of Yamaha Genuine Accessories at ShopYamaha.com ™

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 Bar

This 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! Spare Tire Mount

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 Box

This 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

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:
• 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! 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
a. • 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* b. 15" Light Bar*
2HC-H4104-T0-00 2HC-H4104-P0-00
b.
*Available early October
2015
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
a. • 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* b.15" Light Bar*
2HC-H4104-R0-00 2HC-H4104-M0-00
b. 2015

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
a. Fits ’16 YXZ1000R

a.Spot* b.Flood*
2HC-H4104-V0-00 2HC-H4104-L0-00
2015
b.
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.
• 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! 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 Pods

These simple yet durable modular rear speakers crank out quality sound and bass response.
• 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 Subwoofer

This 10" powered subwoofer is designed to deliver the best sound quality and bass response.
• 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

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 2nd Battery Mount Kit
2HC-H21B0-V0-00 2HC-H212A-V0-00
Available September 2015 Available late September 2015
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! 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
Current Yamaha Accessories Also Available for YXZ1000R

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

™
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.

Dokumen - Tips 2016 Yxz1000r Service Guide Final Ver 2

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MODEL MODEL CODE COLOR NAME COLOR CODE

Body: White (PP*) Body: Bluish White Solid 1 (BWS1)

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

YXZ 1ST - 3RD characters = Product group

Color matched rigid bushing pivot

4-beam LED headlights

Color matched rigid bushing pivot

Front rear brake system

Tilt adjusting, soft-grip

Electric Power Steering

9 gal fuel tank High–capacity

LED tail light

Dry sump external oil

D Wheel base 90.6 in 2300mm

G Tread (rear) 53 in 1346mm

Component: Cylinder Head

EX: 14 degrees IN: 14 degrees

Service Tip In-depth Info

Diameter = 4.5mm 1HX Adjusting

Service Tip In-depth Info

Align 2HC mark with large hole on camshaft flange,

Service Tip In-depth Info

Chain guide “UP” arrow

Service Tip In-depth Info

Disassemble, Clean and Inspect Timing Chain Tensioner

• Apply a small amount of engine oil to each camshaft bearing surface

Component: Air induction system

Fresh air intake

Service Tip In-depth Info

Service Tip In-depth Info

Sectional view of piston ring

80mm 2nd ring

Service Tip In-depth Info

Piston pin oiling holes

Service Tip In-depth Info

Oil to cam chain

Oil spray to cool

Cam chain drive

Service Tip In-depth Info

Service Tip In-depth Info

Component: Engine Oil Pump

Oil Pump Assembly - integrates 2 pumps

Service Tip In-depth Info

• Dry sump oil system

1. Oil pump assembly

Oil pressure less than 2 psi, switch closed

Oil pressure more than 2 psi, switch open

* YDT Monitor Mode line number 21

Balancing holes 19mm

Service Tip In-depth Info

Bearing located in engine

Service Tip In-depth Info

Clutch rod Cam damper

Input from engine

Service Tip In-depth Info

5YU-type friction 2H7-type steel

2H7 steel plate Judder seat

Service Tip In-depth Info

Service Tip In-depth Info

Reverse idler shaft Input shaft cam

Service Tip In-depth Info