2014

ASSEMBLY MANUAL
1XD-F8107-E0
YX70ME
YX70MHE
YX70MNE
YX70MPE
YX70MPHE
YX70MPNE
YXM700DE
YXM700PE
YXM700PHE
EBA00002
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha vehicle
prior to delivery to the customer. Since some external parts of the vehicle have been removed at the
Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be
noted that the assembled vehicle should be thoroughly cleaned, checked, and adjusted prior to delivery
to the customer.
EBA00003
IMPORTANT
The service specifications given in this assembly manual are based on the model as manufactured. Mod-
ifications and significant changes in specifications and/or procedures will be forwarded to authorized
Yamaha dealers.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.
CONCERNING CRATE DAMAGE:
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid dam-
age to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
EBA00001
YX70ME/YX70MHE/
YX70MNE/YX70MPE/
YX70MPHE/YX70MPNE/
YXM700DE/YXM700PE/
YXM700PHE
ASSEMBLY MANUAL
2013 by Yamaha Motor Co., Ltd.
First edition, June 2013
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EBA01001
SYMBOLS USED IN THE ASSEMBLY MANUAL
In order to simplify descriptions in this assembly manual, the following symbols are used:
SYMBOL DEFINITION SYMBOL DEFINITION
Filling fluid Coat with lithium-soap-based grease.
Lubricant
Tighten to 10 Nm.
(10 Nm = 1.0 mkgf, 7.2 ftlbf)
Special tool Towards the front of the vehicle
Tightening torque Clearance required
Wear limit, clearance
Install so that the arrow mark faces
upward.
Engine speed Apply motor oil.
Electrical data Made of rubber or plastics
A: Ref. No. (indicating the order of operations.)
B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
(1): Refer to PARTS LOCATION.
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame and/or con-
tained in the plastic tray (cargo bed)
: Temporarily installed or secured
Example:
(1)-V
(1) signifies the location of the parts and V sig-
nifies that the part is stored in a plastic bag.
E: Size or material of parts
d/D: Diameter of part
: Length of part
e.g., 5 (0.20) = 5 mm (0.20 in)
10
FWD
T

R
.
.
UP
d
D d
d
D d
*
EBA00006
PREPARATION
To assemble the vehicle correctly, supplies (e.g. oils, greases, and shop rags) and sufficient working
space are required.
Workshop
The workshop where the vehicle is assembled should be clean, spacious, and have a level floor.
Self-protection
Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or
when doing any operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves and shoes.
1
EBA00009
PARTS LOCATION
NOTICE
Do not use a cutter, scissors, or other sharp object to open the carton box; otherwise, the
included parts could be damaged.
Wear suitable protective gear such as gloves when handling and opening the carton box.
1. Plastic tray
2. Skid plates
3. Owners manual (located in the glove com-
partment)
4. Plastic bag 1 (located in the glove compart-
ment)
5. Plastic bag 2 (located in the glove compart-
ment)
A. For CDN
B. For Europe and Oceania
3
4
5
2
A
B
3
2
1
2
(1) Plastic tray (for CDN) 1. Rear top frame
2. Front top frame
3. Left side frame
4. Right side frame
5. Rear right frame
6. Rear center frame
7. Rear left frame
8. Headrest
9. Plastic bags 1-4
Plastic bag 1 (for CDN)
(4) Plastic bag 1 (for Europe and Oceania)
1. Flange bolts (front and rear skid plates)
[d = 6 (0.24), = 12 (0.47)]
Plastic bag 2 (for sun top models) (for CDN)
(5) Plastic bag 2 (for sun top models) (for
Europe and Oceania)
1 2 3 4
1
2
3
4
5
8
9
6 7
1
1
2
3
4
5
6
7
8
9
3
1. Sun top front brackets
2. Dampers (sun top front and lower brackets)
3. Sun top rear brackets
4. Dampers (sun top rear brackets)
5. Sun top lower brackets
6. Tapping screws (sun top front and rear brack-
ets)
[d = 6 (0.24), = 16 (0.63)]
7. Flange bolts (sun top lower brackets)
[d = 6 (0.24), = 12 (0.47)]
8. Hexagon socket bolts (sun top lower brackets)
[d = 6 (0.24), = 16 (0.63)]
9. Flange nuts (sun top lower brackets)
[d = 6 (0.24)]
Plastic bag 3 (for CDN)
1. Flange bolts (headrests)
[d = 6 (0.24), = 16 (0.63)]
2. Flange bolts (seat belts)
[d =12 (0.47), = 20 (0.79)]
3. Hexagon socket bolts (seat belts)
[d =11 (0.43), = 32 (1.26)]
4. Washers (seat belts)
[d = 11 (0.43), D = 25 (0.98)]
Plastic bag 4 (for CDN)
1. Flange bolts (left and right side frames)
[d = 10 (0.39), = 45 (1.77)]
2. Self-locking nuts (left and right side frames)
[d = 10 (0.39)]
3. Hexagon socket bolts (left and right side
frames)
[d = 10 (0.39), = 70 (2.76)]
4. Washers (left and right side frames)
[d = 10 (0.39), D = 32 (1.26)]
5. Flange bolts (rear center frame)
[d = 10 (0.39), = 16 (0.63)]
1
2
3
4
1
2
3
4
5
6
4
6. Hexagon socket bolts (front top, rear
top, rear left, and rear right frames)
[d = 10 (0.39), = 20 (0.79)]
(2) Skid plates
1. Front skid plate
2. Rear skid plate
(3) Owners manual
1. Owners manual
Sun top (for sun top models)
1. Sun top
TIP
This part is packaged separately from the vehi-
cle.
1
2
1
1
5
EBA00012
SETUP PROCEDURES
TIP
Before starting the setup, supply the specified tire pressure to the four wheels.
WARNING
_
This model is equipped with low pressure tires. Refer to ADJUSTMENTS AND PREDELIVERY
SERVICE.
Perform the setup procedures in the order indicated by the numbers. Always follow the order as
shown.
3 3 2 2 2 3
1 1
5 6
5
1 1 4 1 1
6
1. ENCLOSURE (for CDN)
A: Install the rear center frame.
B: Temporarily tighten the bolts.
C: Install the left and right side frames.
D: Temporarily tighten the nuts.
E: Install the rear left and right frames.
F: Temporarily tighten the bolts.
G: Install the front and rear top frames.
H: Temporarily tighten the bolts.
I: Tighten the bolts and nuts to specification.
TIP
Tighten the bolts according to the alphabetical
order shown in the illustration.
2. HEADREST (for CDN)
A: Tighten the bolts to specification.
1 Rear center frame 1 (1)-S
2 Flange bolt 4 (1)-S d = 10 (0.39), = 16 (0.63)
3 Left side frame 1 (1)-S
4 Right side frame 1 (1)-S
5 Flange bolt 4 (1)-S d = 10 (0.39), = 45 (1.77)
6 Hexagon socket bolt 2 (1)-S d = 10 (0.39), = 70 (2.76)
7 Washer 4 (1)-S d = 10 (0.39), D= 32 (1.26)
8 Self-locking nut 6 (1)-S d = 10 (0.39)
9 Rear left frame 1 (1)-S
10 Rear right frame 1 (1)-S
11 Hexagon socket bolt 8 (1)-S d = 10 (0.39), = 20 (0.79)
A
1
2
B
2
B
4
6
7 7
8
8
8
8
5
5
6
7 7
D
D
C
3
C
D
E
F
11
F
F
10
E
9
11
11
12 Front top frame 1 (1)-S
13 Rear top frame 1 (1)-S
14 Hexagon socket bolt 8 (1)-S d = 10 (0.39), = 20 (0.79)
T

R
.
.
Bolt and nut
48 Nm (4.8 mkgf, 35 ftlbf)
Nut
65 Nm (6.5 mkgf, 47 ftlbf)
1 Headrest 3 (1)-S
2 Flange bolt 9 (1)-S d = 6 (0.24), = 16 (0.63)
T

R
.
.
Bolt
7 Nm (0.7 mkgf, 5.1 ftlbf)
G
13
G
12
H
14
H
14
H
14
H
14
65
65
48
48
48
48
48
48
b
b
b
b
c
e
e
a
a
a
d
I
1
2
A 7
2
A 7
2
A 7
7
3. SEAT BELT (for CDN)
A: Install the seat belt anchor plates so that
they contact the stopper.
B: Tighten the bolts to specification.
4. SUN TOP (for sun top models)
(1)-V: For CDN
(5)-V: For Europe and Oceania
A: Tighten the bolts, nuts, and screws to speci-
fication.
5. SKID PLATES
(1)-V: For CDN
(4)-V: For Europe and Oceania
A: Tighten the bolts to specification.
6. BATTERY
A: Before installing the battery, charge the bat-
tery.
TIP
Refer to ADJUSTMENTS AND PREDELIV-
ERY SERVICE.
B: First, connect the positive lead (red color
lead) to the positive terminal.
C: Connect the negative leads (black color
lead) to the negative terminal.
1 Seat belt 3
*
2 Flange bolt 3 (1)-V d = 12 (0.47), = 20 (0.79)
3 Washer 3 (1)-V d = 11 (0.43), D= 25 (0.98)
4 Hexagon socket bolt 3 (1)-V d = 11 (0.43), = 32 (1.26)
T

R
.
.
Bolt
59 Nm (5.9 mkgf, 43 ftlbf)
1 Sun top 1
2 Damper 4
(1)-V
(5)-V
3 Sun top rear bracket 4
(1)-V
(5)-V
4 Damper 8
(1)-V
(5)-V
5 Sun top front bracket 4
(1)-V
(5)-V
6 Screw 16
(1)-V
(5)-V
d = 6 (0.24), = 16 (0.63)
7 Sun top lower bracket 2
(1)-V
(5)-V
8 Flange bolt 4
(1)-V
(5)-V
d = 6 (0.24), = 12 (0.47)
9 Hexagon socket bolt 4
(1)-V
(5)-V
d = 6 (0.24), = 16 (0.63)
10 Flange nut 4
(1)-V
(5)-V
d = 6 (0.24)
2
1
1
4
B 59
B 59
B 59
B 59
B 59
2
1
4
2
4
3
3
3
A
A 3 A 3
A 7
4
5
6
6
2
10
9
7 4 4 7 8
1
6
6
3
T

R
.
.
Bolt and nut
7 Nm (0.7 mkgf, 5.1 ftlbf)
Screw
3.0 Nm (0.30 mkgf, 2.2 ftlbf)
1 Front skid plate 1 (2)-S
2 Rear skid plate 1 (2)-S
3 Flange bolt 8
(1)-V
(4)-V
d = 6 (0.24), = 12 (0.47)
T

R
.
.
Bolt
7 Nm (0.7 mkgf, 5.1 ftlbf)
1 Battery 1
*
2 Battery band 2
*
3 Bolt 2
*
d = 8 (0.31), = 20 (0.79)
4 Nut 2
*
d = 8 (0.31)
5 Intake duct cover 1
*
6 Quick fastener 2
*
7 Hood 1
*
A 7 A 7
1
3
3
2
3
3
D 1.5
3
7
C
B
4
4
A
2
1
6
5
8
D: Tighten the nuts to specification.
T

R
.
.
Nut
1.5 Nm (0.15 mkgf, 1.1 ftlbf)
9
CABLE ROUTING
WARNING
Proper cable and lead routing is essential to assure safe vehicle operation.
1. Negative battery lead
2. Positive battery lead
3. Wire harness
4. Battery
1 2
3
4
10
EBA00101
ADJUSTMENTS AND PREDELIVERY SERVICE
Perform the predelivery service in the order indicated by the letters. Always follow the order as shown.
G J,M A
C
K O
B N H,I L L B
B E L L F
D
B N
11
EBA00102
A. CHECKING AND CHARGING THE
BATTERY
TIP
The battery used in this vehicle is a VRLA
(Valve Regulated Lead Acid) battery, it has
been pre-filled with electrolyte at the factory so
there is no need to add fluid at any time.
1. Check:
Using a digital voltmeter, the state of a dis-
charged VRLA (Valve Regulated Lead
Acid) battery can be checked by measuring
open-circuit voltage (the voltage measured
with the positive and negative terminals
being disconnected).
WARNING
Do not attempt boost charging under
any circumstances.
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc. It
contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physi-
cian immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention. Bat-
teries produce explosive gases. Keep
sparks, flame, cigarettes, etc., away.
Ventilate when charging or using in
enclosed space. Always shield eyes
when working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
NOTICE
If the voltage is lower than 12.8 V, the
battery must be charged. If this is not
done, the life of the battery will be short-
ened drastically. Since the procedure for
charging the battery is not explained in
the assembly manual, refer to the ser-
vice manual for more details.
Never remove the strip of caps, nor add
any water or electrolyte.
EBA00105
B. CHECKING THE TIRE PRESSURE
WARNING
Pay attention to the following points:
Recommended tire pressure:
Vehicle load: 0 - 300 kg (0 - 661 lb):
Front: 75 kPa (0.75 kgf/cm
2
, 11 psi)
Rear: 90 kPa (0.90 kgf/cm
2
, 13 psi)
Vehicle load: 300 kg - maximum (661 lb -
maximum)
Front: 75 kPa (0.75 kgf/cm
2
, 11 psi)
Rear: 125 kPa (1.25 kgf/cm
2
, 18 psi)
Maximum vehicle load: 445 kg (981 lb)
Tire size: Front 25 8-12NHS
Rear 25 10-12NHS
1. Excessive tire pressure [over 250 kPa
(2.5 kgf/cm
2
, 36 psi)] may cause tires to
burst. Inflate tires very slowly. Fast infla-
tion could cause tire to burst.
2. Too low a pressure [Front: 70 kPa (0.70
kgf/cm
2
, 10 psi), Rear: 85 kPa (0.85 kgf/
cm
2
, 12 psi)] will cause the tire to dis-
lodge from the rim.
3. Put the same pressure in both rear tires.
Uneven tire pressure will severally affect
the handling.
4. Set tire pressure cold.
1. Check:
Tire pressure

a. Use an appropriate tire pressure air gauge.
Set tire pressures to the following specifica-
tions:
Open-cir-
cuit voltage
Charging time
12.8 V or
higher
Charging is not necessary
Reference tire pressure:
Vehicle load: 0 - 300 kg (0 - 661 lb):
Front: 75 kPa (0.75 kgf/cm
2
, 11 psi)
Rear: 90 kPa (0.90 kgf/cm
2
, 13 psi)
Vehicle load: 300 kg - maximum
(661 lb - maximum)
Front: 75 kPa (0.75 kgf/cm
2
, 11 psi)
Rear: 125 kPa (1.25 kgf/cm
2
, 18 psi)
Minimum tire pressure:
Vehicle load: 0 - 300 kg (0 - 661 lb)
Front: 70 kPa (0.70 kgf/cm
2
, 10 psi)
Rear: 85 kPa (0.85 kgf/cm
2
, 12 psi)
Vehicle load: 300 kg - maximum
(661 lb - maximum)
Front: 70 kPa (0.70 kgf/cm
2
, 10 psi)
Rear: 120 kPa (1.20 kgf/cm
2
, 17 psi)
12
NOTICE
Never use a tire pressure below minimum
specification. The tire could separate from
the wheel under severe operating condi-
tions.

EBA00109
C. CHECKING THE ENGINE OIL LEVEL
1. Place the vehicle on a level surface.
2. Check the engine oil level on a cold engine.
TIP
If the engine was started before checking the
oil level, be sure to warm up the engine suffi-
ciently, and then wait at least 10 minutes until
the oil settles for an accurate reading.
3. Lift the cargo bed.
4. Check:
Engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark Add the
recommended engine oil to the proper level.
TIP
Be sure to insert the dipstick completely into
the oil filler hole after wiping it clean.
NOTICE
_
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use
engine oils with a grade of CD or higher
and do not use oils labeled ENERGY
CONSERVING II.
Do not allow foreign material to enter the
crankcase.
5. Check the engine oil level again.
NOTICE
_
Be sure the engine oil is at the correct
level, otherwise engine damage may result.
6. Lower the cargo bed.
EBA00114
D. CHECKING THE DIFFERENTIAL GEAR
OIL LEVEL
1. Place the vehicle on a level surface.
2. Remove:
Differential gear oil filler bolt 1
3. Check:
Differential gear oil level
The differential gear oil level should be up
to the brim 2 Add the recommended dif-
ferential gear oil to the proper level.
Recommended brand
YAMALUBE
Type
SAE 5W-30, 10W-30, 10W-40, 15W-
40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
Oil quantity (periodic oil change)
Engine
2.20 L (2.33 US qt, 1.94 lmp.qt)
b
a
Recommended oil
SAE 80 API GL-4 Hypoid gear oil
Oil quantity (periodic oil change)
0.18 L (0.19 US qt, 0.16 Imp.qt)
0 10 30 50 70 90 110 130 F
20 10 0 10 20 30 40 50 C
SAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
SAE 20W-50
1
2
13
NOTICE
Take care not to allow foreign material to
enter the differential gear case.
4. Install:
Differential gear oil filler bolt
EBA00115
E. CHECKING THE FINAL GEAR OIL LEVEL
1. Place the vehicle on a level place.
2. Remove:
Final gear oil filler bolt 1
3. Check:
Final gear oil level
The final gear oil level should be up to the
brim of the filler hole.
Below the brim 2 Add the recom-
mended final gear oil to the proper level.
NOTICE
_
Take care not to allow foreign material to
enter the final gear case.
4. Install:
Final gear oil filler bolt
EBA00119
F. CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
2. Check:
Coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark Add the
recommended coolant to the proper level.
NOTICE
_
Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft
water may be used if distilled water is
not available.
3. Start the engine, warm it up for several min-
utes, and then turn it (off).
4. Check:
Coolant level
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
EBA00122
G. ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY
1. Check:
Accelerator pedal free play a
Out of specification Adjust.
2. Adjust:
Accelerator pedal free play

a. Lift the cargo bed.
b. Remove the frame cross member.
c. Remove the throttle valve cover 1.
T

R
.
.
Differential gear oil filler bolt
23 Nm (2.3 mkgf, 17 ftlbf)
Recommended oil
SAE 80 API GL-4 Hypoid gear oil
Oil quantity (periodic oil change)
0.40 L (0.42 US qt, 0.35 Imp.qt)
T

R
.
.
Final gear oil filler bolt
22 Nm (2.2 mkgf, 16 ftlbf)
2
1
Accelerator pedal free play
12.032.0 mm (0.471.26 in)
b
a
a
14
d. Slide back the rubber cover 2.
e. Loosen the locknut 3.
f. Turn the adjusting bolt 4 in direction b or
c until the correct free play is obtained.
g. Tighten the locknut.
h. Slide the rubber cover to its original posi-
tion.
TIP
If the length of d is 8.5mm (0.33 in) or more,
loosen locknut 5 and turn the adjusting nut
6 in direction e or f until the correct free
play is obtained.
i. Check the throttle valve pulley stopper gap.
TIP
When the accelerator pedal is fully depressed
(throttle valve fully open), the gap g between
the throttle valve pulley 7 and the pulley stop-
per 8 should be 1 mm (0.04 in) or less. The
throttle valve pulley should not contact the pul-
ley stopper.
j. Install the throttle valve cover.
k. Install the frame cross member.
l. Lower the cargo bed.

H. ADJUSTING THE BRAKE PEDAL
1. Check:
Brake pedal free play a
Out of specification Adjust.
TIP
The end of the brake rod should lightly contact
the brake master cylinder.
2. Adjust:
Brake pedal free play

a. Loosen the locknut 1.
b. Turn the brake rod 2 in direction b or c
until the correct free play is obtained.
Direction b Free play is increased.
Direction c Free play is decreased.
Direction e Free play is increased.
Direction f Free play is decreased.
1
3
b
c
2
4
e
f
d
5
6
T

R
.
.
Frame cross member bolt
17 Nm (1.7 mkgf, 12 ftlbf)
Brake pedal free play
0 mm (0 in)
g
8
7
a
15
c. Tighten the locknut to specification.
WARNING
After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the front and rear wheels to ensure there is
no brake drag. If any brake drag is noticed
perform the above steps again.

I. ADJUSTING THE BRAKE LIGHT SWITCH
TIP
The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly
adjusted when the brake light comes on just
before the braking effect starts.
1. Check:
Rear brake light operation timing
Incorrect Adjust.
2. Adjust:
Rear brake light operation timing

a. Turn the adjusting nut 1 in direction a or
b until the rear brake light comes on at the
proper time.

J. ADJUSTING THE PARKING BRAKE
LEVER
1. Shift the drive select lever into low gear L.
2. Check:
Parking brake lever free play a
3. Adjust:
Parking brake lever free play

a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction b or
c until the correct free play is obtained.
d. Tighten the locknut to specification.
Direction b Free play is increased.
Direction c Free play is decreased.
T

R
.
.
Brake pedal rod locknut
17 Nm (1.7 mkgf, 12 ftlbf)
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
1
2
b
c
Direction b Free play is increased.
Direction c Free play is decreased.
T

R
.
.
Parking brake lever cable locknut
16 Nm (1.6 mkgf, 12 ftlbf)
a
b
1
a
1
b
c
3
2
16
e. Slide the rubber cover to its original posi-
tion.

EBA00131
K. CHECKING THE BRAKE FLUID LEVEL
1. Place the vehicle on a level surface.
TIP
When checking the brake fluid level, make
sure that the top of the brake master cylinder
reservoir top is horizontal.
2. Check:
Brake fluid level
Below the minimum level mark 1 Add
the specified brake fluid to the proper level.
WARNING
Use only designated brake fluid. Other
brake fluids may cause the rubber seals
to deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
When refilling, be careful that water does
not enter the brake master cylinder res-
ervoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EBA00132
_ _EBA00132
L. BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
Bleed the hydraulic brake system when-
ever:
the system was disassembled,
a brake hose or brake pipe was loosened
or removed,
the brake fluid is very low,
the brake operation is faulty.
A loss of braking performance may occur if
the brake system is not properly bled.
1. Remove:
Front wheel
Rear wheel
2. Bleed:
Hydraulic brake system

a. Add the specified brake fluid to the proper
level.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to
the bleed screw 2.
A. Front brake
B. Rear brake
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake pedal several times.
f. Push down on the pedal and hold it.
g. Loosen the bleed screw and allow the pedal
to travel towards its limit.
Specified brake fluid
DOT 4
1
1
2

1
2

17
h. Tighten the bleed screw when the pedal
limit has been reached, then release the
pedal.
i. Repeat steps (e) to (h) until all the air bub-
bles have disappeared from the fluid.
j. Tighten the bleed screw to specification.
TIP
If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.
k. Add brake fluid to the proper level.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.

3. Install:
Front wheel
Rear wheel
Tighten the nuts 3 to specification.
WARNING
Install the nut with its tapered side towards
the wheel.
EBA00133
M. ADJUSTING THE DRIVE SELECT LEVER
SHIFT CABLE
WARNING
Before moving the drive select lever, bring
the vehicle to a complete stop and take
your foot off the accelerator pedal. Other-
wise the transmission may be damaged.
1. Check:
Drive select lever free play a
Out of specification Adjust the drive
selector shift cable.
2. Adjust:
Drive select lever shift cable length b

a. Loosen the locknut 1.
b. Turn the adjusting nut 2 in direction c or
d until the specified cable length is
obtained.
T

R
.
.
Front brake caliper bleed screw
5 Nm (0.5 mkgf, 3.6 ftlbf)
Rear brake caliper bleed screw
5 Nm (0.5 mkgf, 3.6 ftlbf)
T

R
.
.
Front wheel nut
75 Nm (7.5 mkgf, 54 ftlbf)
Rear wheel nut
75 Nm (7.5 mkgf, 54 ftlbf)
3
Drive select lever free play
4 mm (1.6 in)
Direction c
Shift cable length is
increased.
Direction d
Shift cable length is
decreased.
Drive select lever shift cable length
165 mm (6.50 in)
a
a
c
d
2
1
b
18
TIP
When checking the drive select lever shift
cable length, shift the drive select lever into N
(neutral).
c. Tighten the locknut to specification.
d. Turn the main switch to (on), and then
check that the drive select lever can be
shifted to each shift position and that the
appropriate indicator light comes on when
the lever is in each position.

EBA00138
N. ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
Headlight beam (vertically)
Turn the adjusting screw 1 in direction a
or b.
O. LUBRICATING THE AIR FILTER
ELEMENT
1. Remove:
Center passenger seat cushion 1
2. Remove:
Air filter case cover 2
3. Remove:
Air filter element 3
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
4. Apply:
Yamaha foam air filter oil

a. Squeeze the initial oil out of the element.
NOTICE
Do not twist or wring out the element. This
could damage the foam material.
b. Apply Yamaha foam air filter oil or other
quality foam air filter oil.
c. Squeeze out the excess oil.
TIP
The element should be wet but not dripping.

5. Install:
Air filter element
6. Install:
Air filter case cover
TIP
Fit the holders a on the air filter case cover
onto the projections b on the air filter case,
and then install the air filter case cover by
hooking the holders onto the cover.
T

R
.
.
Drive select lever shift cable locknut
39 Nm (3.9 mkgf, 28 ftlbf)
Direction a
Headlight beam is
raised.
Direction b
Headlight beam is low-
ered.
1
a b
1
2
3
19
7. Install:
Center passenger seat cushion
a
b
20
EBA00200
APPENDICES
SERVICE DATA
EBA00210
STANDARD EQUIPMENT
EBA00220
OWNERS TOOL KIT
Engine idling speed 15501650 r/min
Spark plug
Type/Manufacturer CPR7EA-9/NGK
Gap 0.80.9 mm (0.0310.035 in)
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 36.7 L (9.70 US gal, 8.07 Imp.gal)
Valve clearance (cold)
IN 0.090.13 mm (0.00350.0051 in)
EX 0.160.20 mm (0.00630.0079 in)
1. Owners manual 1 pc.
2. Owners tool kit 1 pc.
3. Tire pressure gauge
[measurement range: 55110
kPa (0.551.10 kgf/cm
2
, 816 psi)]
1 pc.
4. Tire pressure gauge
[measurement range: 70400
kPa (0.704.00 kgf/cm
2
,
1057 psi)]
1 pc.
5. Safety handbook (for CDN) 1 pc.
1. Owners tool bag 1 pc.
2. Spark plug wrench 1 pc.
3. Screwdriver grip 1 pc.
4. Screwdriver bit
(Phillips head and slotted head)
1 pc.
5. Pliers 1 pc.
6. Wrench (10-12) 1 pc.
7. Wrench (14-17) 1 pc.
21
EBA00230
TIGHTENING TORQUE
Part to be tightened
Thread
size
Tightening torque
Nm mkgf ftlbf
Engine:
Spark plug M10 13 1.3 9.4
Engine oil drain bolt M14 30 3.0 22
Chassis:
Engine mounting bolt (front side) M10 42 4.2 30
Engine mounting bolt (rear side) M6 10 1.0 7.2
Engine bracket nut M10 42 4.2 30
Front fender and front grill bolt M6 4.0 0.40 2.9
Radiator bracket bolt M6 7 0.7 5.1
Radiator pipe holder bolt M6 7 0.7 5.1
Front fender and electrical components tray bolt M6 4.0 0.40 2.9
Front grill and front guard bolt M6 4.0 0.40 2.9
Front grill and frame bolt M6 4.0 0.40 2.9
Headlight screw M5 1.5 0.15 1.1
Front fender and frame bolt M6 4.0 0.40 2.9
Electrical components tray and frame bolt M6 4.0 0.40 2.9
Muffler heat protector bolt M8 17 1.7 12
Side panel bolt M6 4.0 0.40 2.9
ECU nut M6 7 0.7 5.1
Lean angle sensor bolt M5 3.8 0.38 2.8
Starter relay lead bolt M6 3.6 0.36 2.6
Positive battery lead nut M8 1.5 0.15 1.1
Negative battery lead nut M8 1.5 0.15 1.1
EPS control unit bolt (for EPS models) M6 2.5 0.25 1.8
V-belt cooling intake duct joint 1 clamp screw (V-belt cooling
intake duct side)
M4 1.5 0.15 1.1
V-belt cooling intake duct joint 1 clamp screw (drive belt cover
side)
M6 2.0 0.20 1.4
V-belt cooling intake duct joint 2 clamp screw M4 1.5 0.15 1.1
V-belt cooling exhaust duct joint clamp screw (V-belt cooling
exhaust duct side)
M4 1.5 0.15 1.1
V-belt cooling exhaust duct joint clamp screw (drive belt cover
side)
M6 2.0 0.20 1.4
Fuel tank retainer bolt M8 16 1.6 12
Fuel tank bolt M6 7 0.7 5.1
Fuel tank bracket bolt M6 7 0.7 5.1
Fuel tank breather hose joint bolt M6 7 0.7 5.1
Fuel pump nut M6 See TIP.
Throttle body joint clamp screw M5 2.8 0.28 2.0
Intake air silencer joint clamp screw (throttle body side) M5 3.5 0.35 2.5
Intake air silencer joint clamp screw (intake air silencer side) M6 2.0 0.20 1.4
Air filter case joint clamp screw M6 2.0 0.20 1.4
Air intake duct joint clamp screw M6 2.0 0.20 1.4
22
Air filter case bolt M6 7 0.7 5.1
Coolant reservoir bolt M6 7 0.7 5.1
Door hinge nut M6 1.3 0.13 0.94
Door hinge bolt M6 7 0.7 5.1
Door handle latch nut M6 7 0.7 5.1
Front skid plate bolt M6 7 0.7 5.1
Rear skid plate bolt M6 7 0.7 5.1
Lower panel and floor board bolt M6 4.0 0.40 2.9
Lower panel and frame bolt M6 7 0.7 5.1
Frame cross member bolt M8 17 1.7 12
Exhaust pipe heat protector M6 17 1.7 12
Exhaust pipe heat protector M6 7 0.7 5.1
Front wheel axle nut M24 350 35 253
Front wheel nut M12 75 7.5 54
Rear wheel axle nut M24 350 35 253
Rear wheel nut M12 75 7.5 54
Front brake disc guard bolt M6 9 0.9 6.5
Front brake caliper bolt M10 48 4.8 35
Front brake disc bolt M8 30 3.0 22
Front brake caliper retaining pin M8 22 2.2 16
Front brake pad bolt M10 17 1.7 12
Front brake caliper guide pin M8 17 1.7 12
Front brake caliper bleed screw M8 5 0.5 3.6
Rear brake disc guard bolt M6 9 0.9 6.5
Rear brake disc cleaning plate bolt M6 9 0.9 6.5
Rear brake disc bolt M8 30 3.0 22
Rear brake caliper bolt M10 48 4.8 35
Rear brake caliper retaining pin M8 22 2.2 16
Rear brake pad bolt M10 17 1.7 12
Rear brake caliper guide pin M8 17 1.7 12
Rear brake caliper bleed screw M8 5 0.5 3.6
Brake pipe flare nut M10 19 1.9 14
Front brake hose joint bolt M6 10 1.0 7.2
Rear brake hose joint bolt M6 10 1.0 7.2
Front brake hose holder bolt M6 7 0.7 5.1
Rear brake hose holder bolt M6 7 0.7 5.1
Front brake hose union bolt M10 27 2.7 20
Rear brake hose union bolt M10 27 2.7 20
Brake master cylinder reservoir cap 3.5 0.35 2.5
Brake master cylinder reservoir clamp screw M6 6 0.6 4.3
Parking brake cable holder M6 12 1.2 8.7
Parking brake caliper guide pin M8 17 1.7 12
Parking brake caliper guide pin nut M8 22 2.2 16
Parking brake pad bolt M8 17 1.7 12
Part to be tightened
Thread
size
Tightening torque
Nm mkgf ftlbf
23
Parking brake caliper arm nut M8 17 1.7 12
Brake master cylinder bolt M8 16 1.6 12
Pedal assembly bolt M8 16 1.6 12
Brake pedal rod locknut M8 17 1.7 12
Throttle cable locknut (accelerator pedal end) M6 2.5 0.25 1.8
Parking brake lever bolt M6 13 1.3 9.4
Parking brake caliper bolt M10 40 4.0 29
Parking brake disc nut M6 10 1.0 7.2
Parking brake cable locknut M6 16 1.6 12
Front upper arm nut M10 45 4.5 33
Front lower arm nut M10 45 4.5 33
Front shock absorber assembly nut M10 45 4.5 33
Front upper arm and steering knuckle nut M12 30 3.0 22
Front lower arm and steering knuckle nut M12 30 3.0 22
Front arm protector bolt M6 7 0.7 5.1
Steering wheel nut M12 35 3.5 25
Steering column bolt (except for EPS models) M8 21 2.1 15
Steering joint bolt M8 27 2.7 20
Steering assembly bolt M10 See TIP.
Tie-rod end locknut M12 40 4.0 29
Steering knuckle and tie-rod end nut M12 39 3.9 28
EPS unit bolt (for EPS models) M8 21 2.1 15
EPS unit bracket bolt (for EPS models) M6 10 1.0 7.2
Rear upper arm nut M10 45 4.5 33
Rear lower arm nut M10 45 4.5 33
Rear shock absorber assembly nut M12 82 8.2 59
Stabilizer joint nut M10 60 0.6 43
Stabilizer holder bolt M10 85 8.5 61
Rear upper arm and rear knuckle nut M12 85 8.5 61
Rear lower arm and rear knuckle nut M12 85 8.5 61
Rear arm protector bolt M6 7 0.7 5.1
Rear knuckle grease nipple M6 3.8 0.38 2.8
Differential gear oil filler bolt M14 23 2.3 17
Differential gear oil drain bolt M10 10 1.0 7.2
Differential motor bolt M6 11 1.1 8.0
Front drive shaft yoke nut M14 62 6.2 45
Differential case bolt M8 24 2.4 17
Front drive shaft universal yoke joint nut M16 150 15 108
Differential assembly nut M12 105 10.5 76
Differential assembly bolt M10 60 6.0 43
Support bearing bracket bolt M8 18 1.8 13
Final gear oil filler bolt M10 23 2.3 17
Final gear oil drain bolt M10 23 2.3 17
Final drive assembly bracket bolt M8 33 3.3 24
Part to be tightened
Thread
size
Tightening torque
Nm mkgf ftlbf
24
Final drive assembly nut M12 105 10.5 76
Rear drive shaft yoke nut M14 97 9.7 70
Final drive pinion gear bearing housing bolt M8 26 2.6 19
Ring gear stopper nut M8 16 1.6 12
Final drive case cover bolt M10 52 5.2 38
Driver seat frame bolt M8 23 2.3 17
Center passenger seat frame bolt M8 23 2.3 17
Outer passenger seat frame bolt M8 23 2.3 17
Seat back bolt M6 6 0.6 4.3
Headrest bolt M6 7 0.7 5.1
Seat belt bolt M12 59 5.9 43
Seat belt buckle bolt M12 59 5.9 43
Seat belt guide bolt M11 59 5.9 43
Handhold bracket bolt M8 16 1.6 12
Handhold stopper nut M6 3.0 0.30 2.2
Left floor board and frame bolt M6 4.0 0.40 2.9
Center floor board and frame bolt M6 4.0 0.40 2.9
Right floor board and frame bolt M6 4.0 0.40 2.9
Left floor board and center floor board bolt M6 4.0 0.40 2.9
Center floor board and right floor board bolt M6 4.0 0.40 2.9
Instrument panel bolt M6 4.0 0.40 2.9
Meter assembly nut M5 3.8 0.38 2.8
Meter assembly bracket bolt M6 7 0.7 5.1
Glove compartment latch plate screw M4 1.3 0.13 0.94
Gas spring assembly ball stud nut M8 16 1.6 12
Tailgate cable bolt M6 7 0.7 5.1
Tail/brake light nut M6 7 0.7 5.1
Cargo bed release lever bolt M6 7 0.7 5.1
Cargo bed release lever holder bolt M6 7 0.7 5.1
Cargo hook nut M6 7 0.7 5.1
Tailgate shaft bolt M6 7 0.7 5.1
Tailgate cable bracket bolt M6 9 0.9 6.5
Cargo bed heat protector M6 8 0.8 5.8
Left side frame nut (front side) M10 65 6.5 47
Left side frame nut (rear side) M10 48 4.8 35
Right side frame nut (front side) M10 65 6.5 47
Right side frame nut (rear side) M10 48 4.8 35
Front top frame bolt M10 48 4.8 35
Rear top frame bolt M10 48 4.8 35
Rear center frame bolt M10 48 4.8 35
Rear left frame bolt M10 48 4.8 35
Rear right frame bolt M10 48 4.8 35
Front guard bolt M10 48 4.8 35
Front guard cover screw M6 2.5 0.25 1.8
Part to be tightened
Thread
size
Tightening torque
Nm mkgf ftlbf
25
TIP
Enclosure bolt and nut
Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.
Enclosure tightening sequence:
TIP
Steering assembly bolt
Tighten the steering assembly bolts to 48 Nm (4.8 mkgf, 35 ftlbf) in the proper tightening sequence.
Steering assembly tightening sequence:
TIP
Fuel pump nut
Tighten the fuel pump nuts to 7 Nm (0.7 mkgf, 5.1 ftlbf) in the proper tightening sequence.
Sun top holder screw (for sun top models) M6 3.0 0.30 2.2
Sun top holder nut (for sun top models) M6 7 0.7 5.1
Sun top holder bolt (for sun top models) M6 7 0.7 5.1
Sun top lower bracket bolt (for sun top models) M6 7 0.7 5.1
Sun top lower bracket nut (for sun top models) M6 7 0.7 5.1
Intake air temperature sensor screw M5 1.5 0.15 1.1
Rectifier/regulator bolt M6 7 0.7 5.1
Ground lead bolt M6 7 0.7 5.1
Ignition coil bolt M6 7 0.7 5.1
Horn bolt (for Europe and Oceania) M6 7 0.7 5.1
Horn lead nut (for Europe and Oceania) 2.3 0.23 1.7
Part to be tightened
Thread
size
Tightening torque
Nm mkgf ftlbf
2
1
5
3
3
4
4
5
2
2
1
1
1
2
3
2 4
1
FWD
26
Fuel tank tightening sequence:
TIP
Fuel tank bolt
Tighten the fuel tank bolts and fuel tank retainer bolts to specification in the proper tightening
sequence.
Fuel tank tightening sequence:
TIP
Final drive assembly bolt and nut
Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.
Final drive assembly tightening sequence:
6
1
3
5
2 4
1 2
5 4
3
6
4
9
8
2
1
7
3
5
FWD
white : customer copy / yellow : dealer copy YMC-PDIEN-00-OV
SSV Pre-delivery Inspection Checklist


ASSEMBLY
1. Inspect for shipping damage and missing parts.
2. Assemble per Yamaha Assembly Manual and specifications.
3. Clean and inspect product to exceed customers expectations.
4. Install skid plates, roof supports, seat belt stay and roof (if applicable).
PRE-DELIVERY INSPECTION
If any item of this schedule is found to be defective, take the necessary action and re-test.
Brakes
1. Inspect brake system for correct operation and performance.
2. Check and adjust parking brake operation.
3. Clean brake discs using an oil-free solvent (if applicable).
Clutch
4. Check for correct clutch operation.
Fluid Levels
5. Check and adjust brake reservoir fluid level (if applicable).
6. Drain carburetor float bowl.
7. Check and adjust engine oil level.
8. Check and top-up front and rear gear housing oil levels.
Drive System
9. Check and adjust the shift linkage as necessary.
Cooling System (if applicable)
10. Check and adjust coolant strength and level.
11. Visually inspect coolant system.
12. Bleed coolant system if necessary.
Fuel System
13. Remove, clean and oil air filter as per Service Manual with Yamaha-approved
air filter oil and re-install.
14. Check and adjust full choke operation.
15. Check fuel system for leaks and operation.
16. Install correct fuel as per Owners Manual requirements.
Throttle System
17. Check for correct throttle cable routing, adjustment and operation.
Wheels/Tires
18. Check wheel nuts for correct torque.
19. Check and adjust tire pressures as per the Owners Manual.
20. Check and adjust wheel alignment as required.
Suspension
21. Lubricate all grease points.
22. Check suspension settings and operation.
Steering and Controls
23. Check for smooth steering operation.
24. Check for steering wheel alignment.
25. Check and adjust controls for fit and comfort.
Electrical System
26. Charge battery (if applicable) as per Yamaha specifications.
27. Check all lights including safety-warning systems.
28. Check and adjust starter system, including safety switches.
Other Items
29. Check all fasteners, nuts and bolts.
30. Seat belts (if applicable) check smooth operation and proper latching.
31. Cargo bed check for proper latching.
Test Ride
32. Instrumentation and warning lights/systems.
33. Brake operation.
34. Cold and hot start performance.
35. Gear change, clutch, forward and reverse operation.
36. Engine performance, throttle response and idle speed.
37. Steering and suspension ride quality and comfort.
Post-Test
38. Recheck engine oil level.
39. Check for coolant, oil and fluid leaks.
40. Inspect all bodywork for paint damage and defects.
41. Clean all areas prior to final delivery.
Comments:
YEAR ____________ MODEL __________________________ VIN ___________________________________ ENGINE # ___________________
DATE_________________ Place a check mark only when completed. KEY # ______________________
DEALER STAMP










Assembly Date (YYYYMMDD): ____________
I ___________________________ confirm that I have assembled the above
listed product to the full specifications listed and notified to me by Yamaha
Motor Canada Ltd. in regards to assembly and that it is damage free and
ready for the pre-delivery operation and customer set-up.
Pre-Delivery Inspection Date: ____________
I ___________________________ confirm that I have carried out the PDI as
per Yamaha Motor Canada Ltd. requirements and specifications listed in this
document. I have also visually inspected this product. I have adjusted the
required items to meet all specifications.
Test Ride Date: ____________
I ___________________________ have tested the product and confirm that
it meets all requirements for this product. It has been cleaned and prepared
for delivery to the new owner. The Owners Manual is available and the
license plate (if applicable) is suitably installed.
Technicians signature___________________________________________
Salespersons signature _________________________________________
The Warranty has been fully explained. Yes No
The dealer has explained the benefits of
Yamalube engine oil. Yes No
Yamaha Protection Plus
Yamaha Protection Plus has been explained
and offered to me. Yes No
Yamaha Protection Plus has been purchased. Yes No
The dealer has provided me warranty information
as per Bill 60, Quebec CPA La Loi sur la protection
du consommateur et le domaine de lautomobile. Yes No
I have inspected the product and found that it meets all of my expectations
and that there are no outstanding issues to be discussed with the dealer. The
Owners Manual, Warranty Guide and tool kit have been supplied and
explained to me.
Signed _______________________________________________________
Customer name________________________________________________
Date of delivery ________________________________________________
Customer comments ____________________________________________

_____________________________________________________________