YX Motors YXQUAD X Manual

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INTRODUCTION

Congratulations on your purchase.lt represents the result of many years of experience in the production

of fine sporting,touring,and pace-setting racing vehicles. With the purchase, you can now appreciate

the high degree of craftsmanship and reliability that have made a leader in these fields.

This manual will provide you with a good basic understanding of the features and operation of this

vehicle. It also includes basic maintenance and inspection procedures. If you have any questions

regarding the operation or maintenance of your vehicle, please consult a dealer.

Please read this manual carefully before operating this vehicle. Do not attempt to

opertate this vehicle until you have attained adequate knowledge of its controls

and operating features. Regular inspections and careful maintenance, along with

good operating techniques, will help ensure that you safely enjoy the capabilities

and reliability of this vehicle.

Table of Contents

Troubleshooting

Summary of Contents for YX Motors YXQUAD X

Page 1 INTRODUCTION Congratulations on your purchase.lt represents the result of many years of experience in the production of fine sporting,touring,and pace-setting racing vehicles. With the purchase, you can now appreciate the high degree of craftsmanship and reliability that have made a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this vehicle.
Page 2 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. 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 po- tential personal injury hazards.
Page 3 IMPORTANT NOTE ABOUT USE This vehicle is designed and manufactured for off-road use only. Use on public streets, roads, or highways is not only illegal in most areas, it also increases the risk of an accident involving other vehicles. This vehicle does not meet federal motor vehicle safety standards for on-road use.
Page 4: Table Of Contents
CONTENTS Seat belts........... 4-17 LOCATION OF THE WARNING AND Glove compartment......4-18 SPECIFICATION LABLES....Cargo bed......... 4-19 Front and rear shock absorber SAFETY INFORMATION...... adjustment......... 4-21 Trailer hitch bracket and receiver..4-23 DESCRIPTION........Auxiliary DC jack......4-23 INSTRUMENT AND CONTROL FOR YOUR SAFETY PRE-OPERATION FUNCTIONS........
Page 5 Swtiches..........Doors..........Control cables........Passenger handholds......Tires..........Seat and hip restraints......7-10 Floorboard......... 7-11 OPERATION........Steering wheel........7-11 Engine brake-in......... LEARNING TO OPERATE YOUR Starting the engine......VEHICLE........... 7-12 Drive select lever operation and reverse Personal protective equipent....7-12 driving..........Practice for new users....
Page 6 Uphill........... Coolant..........8-21 7-20 Downhill..........Axle boots......... 8-23 7-21 Rough terrain........Spark plug inspection......8-24 7-22 Cleaning the air filter element....8-26 Pavement.......... 7-22 Drive select lever box check hose..8-31 Water..........7-22 Loose terrain/slippery terrain....V-belt case drain plug......8-32 7-23 Brush or wooded areas......
Page 7 Wheel removal........Emission Control System Warranty..12-1 8-43 Tire replacement....... 8-44 Wheel installation....... 8-45 Battery..........8-46 Battery maintenance......8-47 Fuse replacement......8-51 Replacing a headlight bulb....8-53 Headling beam adjustment....8-55 Tail/brake light bulb replacement..8-56 Troubleshooting......... 8-58 Troubleshooting charts....... 8-59 Cleaning and storage......
Page 12: Safety Information
SAFETY INFORMATION Be a responsible owner As the vehicle’s owner, you are responsible for the safe and proper operation of your X. While YXQUAD understanding all parts of this manual are important for vehicle ownership, be sure to read this chapter and the instructions in Chapeter 7 before operating the YXQUAD X.
Page 13 Before you operate the YXQUAO X Prepare yourself and your passenger: This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle license. This vehicle is designed to carry the driver and one passenger. Never carry passengers in the cargo bed.
Page 14 Prepare your vehicle Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operating condition. Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. See pages 5-1-5-2 for a list of pre-operation checks. Prepare your load or trailer Carrying loads, towing a trailer, or pulling objects can affect handling, stability, and risk of overturn or other accidents.
Page 15 Abrupt maneuver or aggressive driving, enven on flat, open areas, can cause loss of control, including rollovers. The YXQUAD X has higher ground clearance and other features to handle rug- ged terrain, and, as a result, can overturn in situations where some other vehicles may not.
Page 16 Avoid rollovers: Use care when turining: Turning the steering wheel too far or too fast can result in a rollover. Avoid sideways sliding, skidding, or fishtailing, and never do donuts. Slow down before entering a turn and avoid hard braking in a turn. When making tight turns from a stop or at slow speeds, avoid sudden or hard acceleration.
Page 17 Drive straight up and down inclines, not across them. If crossing a hill is unavoidable, drive slowly and turn downhill immidiately if you feel the vehilcle may tip. Avoid paved surfaces. Turn gradually and go slowly if you must drive on pavement. This vehicle is designed for off-road use only.
Page 18 When loaded with cargo or towing a trailer: Reduce speed, operate in low gear only, and allow more room to stop. Avoid hills and rough terrain. Use extreme caution when towing or carrying a load on inclines. Load trailer properly and use extra care when towing or pulling. Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch(if installed).
Page 19 Avoid carbon monoxide poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness,drowsiness, nausea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust.
Page 20 Genuine Accessories Choosing accessories for your YXQUAD X is an important decision. Genuine Accessories which are YXQUAD available only from a dealer, have been designed, tested, and approved for use on your Many companies with no connection to manufacture parts and accessories or offer other modifications for vehicles.
Page 21 Aftermarket tires and rims The tires and rims that came with your YXQUAD X were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort, Other tires, rims, sizes, and combinations may not be appropriate. 2-10...
Page 27 Neutral indicator light “ N” On-Command four-wheel-drive/differ- ent5 gear lock indicator “ ” / “ ” This indicator light comes on when the drive se- lect lever is in the “ N ” position. The On-Command four-wheel-drive indicator “ ” comes on when the On-Command four-wheel-drive Reverse indicator light “...
Page 28 Coolant temperature warning light “ ” If the coolant temperature reaches a specified level, this light comes on to warn that the coolant tem- perature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
Page 31 Clock, hour meter and voltage display To set the clock modes 1. Set the display to the clock. 2. Push the “Clock/Hour” button until the clock starts flashing. 3. Set the hours by pushing the “H” button. 4. Set the minutes by pushing “M” button. 5.
Page 32 Fuel meter This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective all the display segments and fuel level warning indicator will start flashing. If this occurs have a dealer check the electrical circuit. 1. Fuel level warning indicator 2.
Page 33: Switches
NOTICE Switches Do not use the headlights with the en- gine turned off for an extended period of time. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. 1.
Page 34 On-Command four-wheel-drive and dif- Four-wheel dirve (“4WD”): Power is applied to ferential gear lock switches the rear wheels and front wheels. Four-wheel dirve with the differential gear locked (“4WD-LOCK”): Power is supplied to the rear and front wheels with the differential gear locked. Unlike the 4WD mode, all wheels turn at the same speed regardless of traction.
Page 35: Accelerator Pedal
Accelerator pedal Brake pedal Press the accelerator pedal down to increase en- Press the brake pedal to slow or stop the vehicle. gine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before start- ing the engine.
Page 36: Parking Brake Lever
Parking brake lever The parking brake lever is located at the right side of the driver’s seat. It will help keep the vehicle from moving while parked. To set the parking brake, pull the lever up completely. To release the parking brake, pull up on the lever, press the release button, and push the lever all the way down.
Page 37: Drive Select Lever
Drive select lever Fuel tank cap Rem ove the f uel tank cap by turning it The drive select lever is used to shift the vehicle into the low, high, neutral, and reverse positions. counterclockwise. (Refer to pages 6-4-6-5 for the drive select lever operation.) 1.
Page 38: Doors
Doors Seats To open a door, simply pull the latch outward. To To remove a seat, pull its seat lock lever upward, close a door, push or pull the door inward unitl is lift the front of the seat, and then slide the seat securely latched.
Page 39: Seat Belts
To install a seat, insert the projections on the rear of the seat into the seat holders and push down on the seat at the front. Make sure the seats are securely latched. A loose seat could cause the operator to lose control, or cause the operator ①...
Page 40: Glove Compartment
Glove compartment Cup holders NOTICE Be sure to tightly close the cap of any plastic bottle before placing it in a cup holder. To protect from damage, do not put Some plastic bottles may not fit into the cup hold- metal products, like tools or sharply ers depending on their size and shape.
Page 41: Cargo Bed
Cargo bed ① ② 1. Cargo bed 2. Tailgate 3. Cargo hook(X4) 1. Storage/cup holder(X1) 2. Cup holder(X2) Maximum load limit: 181 kg(400 lb) For additional loading information, see page 6-9_6-11. 4-17...
Page 42 Opening and closing the tailgate Lifting and lowering the cargo bed 1. Cargo bed release lever 1. Tailgate 2. Latch(X2) To open To lift Unhook the latches, and then lower the tailgate. Push down the cargo bed release lever on the left or right side of the To close vehicle, and then slowly lift up the Place the tailgate in the original position, and then...
Page 43: Front And Rear Shock Absorber Adjustment
Front and rear shock absorber To lower adjustment With hands and fingers clear of pinch points, lower the cargo bed slowly to its original position and be The spring preload can be adjusted to suit the op- sure it in locked into place. erating conditions.
Page 44 Adjust the spring preload as follows: A special wrench can be obtained at a dealer to To increase the spring preload, turn the adjusting make this adjustment. ring in direction a . To decrease the spring preload, turn the adjusting Standard postion: B ring in direction b .
Page 46: Auxiliary Dc Jack
NOTICE Do not use accessories requiring more than the maximum capacity stated above. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running, the battery will lose its charge and engine starting may 1.
Page 47: For Your Safety Pre-Operation Checks
FOR YOUR SAFETY - PRE - OPERATION CHECKS Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Page 48 ITEM ROUTINE PAGE Accelerator Check for proper accelerator pedal operation. Seat belts Check for proper operation and belt wear. Steering Check for proper operation. Fitting and fasten- Check all fittings and fasteners. L i g h t s a n d Check for proper operation.
Page 49: Front And Rear Brakes
Front and rear brakes Brake fluid leakage Check to see if any brake fluid is leaking out of Brake pedal the pipe joints or the brake fluid reservoir. Apply Check for correct brake pedal free play. If the brake the brakes firmly for one minute. If there is any pedal free play is incorrect, have a dealer adjust leakage, have the vehicle inspected by a dealer.
Page 50: Fuel
Fuel 4. Be sure the fuel tank cap is closed securely. Make sure there is sufficient gasoline in the tank. Gasoline is poisonous and can cause Gasoline and gasoline vapors are ex- injury or death. Handle gasoline with tremely flammable, To avoid fires and care.
Page 52: Engine Oil
Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See papes 8-10_5-15) NOTICE In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemi- cal additives with oil. Do not use oils with a diesel specification of “CD”...
Page 53: Coolant
Coolant Final gear oil Check the coolant level in the coolant reservoir Make sure the final gear oil is at the specified level. when the engine is cold (the coolant level will vary Add oil as necessary. (See pages 8-16_8-18 for with engine temperature).
Page 54: Accelerator Pedal
Accelerator pedal A crash can damage the restraint systems in your Check to see that the accelerator pedal operates vehicle. A damaged restraint system may not prop- correctly. It must operate smoothly and spring back erly protect the person using it , resulting in seri- to the idle position fully when released.
Page 55 Lights Tires Check tire pressure regularly to make sure it is at Check the headlights and tail/brake lights to make the recommended specifications. Also check for sure they are in working condition. Repair as nec- essary for proper operation. wear and damage. Tires pressure Switches Use the tire pressure gauge to check and adjust...
Page 56 Set tire pressures to the following specifications: Recommeded Maximum Minimum Pressure 63 kpa 70 kpa 77 kpa (0.63kgf/cm Front (0.70 kgf/cm (0.77 kgf/cm 9 psi) 10 psi) 11 psi) 91 kpa 98 kpa 105 kpa Rear (0.91kgf/cm (1.05 kgf/cm (0.98 kgf/cm 13 psi) 15 psi) 14 psi)
Page 57 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 1. Tire wear limit 5-11...
Page 58: Engine Brake-In
OPERATION Engine break-in There is never a more important period in the life Read the Owner’s Manual carefully to become fa- of your vehicle than the periold between zero and miliar with all controls. If there is a control or 20 hours.
Page 59: Starting The Engine
Starting the engine Each full-throttle acceleration sequence should be 1. Turn the main switch to “ON”. followed with a substantial rest peridoc for the NOTICE engine, by cruising at lower r/min so the engine The coolant temperature warning light can rid itself of the temporary build-up of heat. If and engine trouble warning light should any abnormality is noticed during this period, con- come on, then go off.
Page 60 The engine can be started in any gear if the For maximum engine life, never accelerate hard brake is applied. However, it is recommeded when the engine is cold! to shift into neutral before starting the engine. 4. With your foot off the accelerator pedal, start the engine by turning the key to “START”.
Page 61: Drive Select Lever Operation And Reverse Driving
Drive select lever operation and reverse 2. Apply the brake pedal, then shift by moving driving the drive select lever along the shift guide. Make sure that the drive select lever is com- NOTICE pletely shifted into position. Do not shift without coming to a com- plete stop and waiting for the engine to return to normal idle speed.
Page 62 Shifting: neutral to reverse Before you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly. Hitting an obstacle or person could result in serious injury or death. 1. Drive select lever Stop the vehicle.
Page 63: On-Command Four-Wheel-Drive Switch
On-Command four-wheel-drive switch “2WD” / “4WD” and differential gear lock switch To change from 2WD to 4WD, stop the vehicle, and then set the switch to “4WD”. When the ve- You may notice that the vehicle handles differently hicle is in 4WD, the four-wheel-drive indicator “ ”...
Page 64 On-Command differential gear lock To lock the differential gear in 4WD, stop the switch “4WD” / “LOCK” vehicle, make sure the On-Command four wheel- drive switch is set to “4WD”, move the differential gear lock lever to position b , and then set the switch to “LOCK”.
Page 65: Parking
Parking Driving before the differential gear lock is When parking, stop the engine and shift the drive properly engaged (e.g., when the indicator select lever into the neutral position. Apply the and indicator light are flashing) will cause the parking brake to help prevent the vehicle from engine speed to be limited unitl engagement rolling, S pages 7-17_7-18 for more information on is complete.
Page 66: Loading
Loading Do not exceed the Maximum tongue weight. Take extra precautions when drivng with a load or Make sure the load does not inter- trailer. Follow these instructions and always use fere with your control or ability to common sense and good judgement when carry- see where you are going.
Page 67 Use the hooks equipped on the cargo bed to tie MAXIMUM LOADING LIMIT down loads. Vehicle loading limit (total weight of cargo, operator, passenger and acces- Choose a trailer hitch drawbar designed for use sories and tongue weights 367 kg (809 with a 5 cm(2 in) receiver.
Page 68 Never exceed the Pull- Reduce speed, operate in low gear ing Load limit of the YXQUAD X. Avoid pull- only, and allow more room to stop. ing on inclines. A heavier vehicle takes longer to Pulling objects on the ground can be more haz- stop.
Page 69: Basic Guide For Safe Use
KNOW YOUR VEHICLE SAFE USE This off-road vehicle will handle and maneuver dif- ferently from cars, ATVs, go-carts, golf-cars and As a YXQUAD X owner you are responsible for the YXQUAD grounds-keeping vehicles. This X has higher safe and proper operation of this vehicle. Read this...
Page 70 Doing things with a YXQUAD X that some people do for thrills in other vehicles (such as side-ways sliding,skidding, fishtailing, or donuts) have led to side rollovers. These rollovers can result in crushed limbs and other serious injuries or death to drivers or passengers.
Page 71: Driver Requirements
YXQUAD X can be used. The driver must be able to place both feet flat on the floorboard while seated upright with his/ her back against the seat back.
Page 72: Passenger Requirements
Passenger requirements Occupant protection system This vehicle is designed for the operator and one passenger. Carrying passengers improperly can ① lead to serious injury or death. As the operator, ② you are responsible for your passenger. Your passenger must be able to place both feet on the floorboard while seated upright with his/ her back against the seat back.
Page 73 You are responsible for any such changes to the vehicle. The YXQUAD X comes with a variety of features to help reduce the risk of driver and passenger injury. These features work together, and when properly used, these features will help protect the occu- pants in the event of an accident.
Page 74: Protective Structure
Protective structure Seat belts The vehicle cage/frame provides a protective struc- Seat belts should be worn by both driver and ture that helps limit intrusions by branches or other passenger. Driver must be sure that the passen- objects and may reduce your risk of injury in ger is belted before driving.
Page 75 An unbelted occupant may strike the interior of the vehicle, the protective structure, or other ob- jects in an accident or during operation. You may also fall completely out or be partially ejected from the vehicle, which may lead to being crushed be- tween the ground and the vehicle.
Page 76 If the latch plate is not positioned in the cor- Put the lap portion of the belt low on your hips. rect location along the seat belt, squeeze the Pull up on the shoulder part so the belt is snug latch plate ends together along its long edges across your hips.
Page 77: Doors
Passenger handholds Doors Handholds are provided to trip during opeartion to The doors are designed to reduce the likelihood maintain proper position and balance. Holding onto that you will stick your leg out to stop the vehicle the handholds helps to reduce the likelihood that from tipping over or for any other reason in rollover.
Page 78: Seat And Hip Restraints
Seat and hip restraints The Seat and hip restraints are designed to help keep you in the vehicle. Do not hold onto hip re- straint bar when the vehicle is moving. Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover.
Page 79: Floorboard
Floorboard Steering wheel The floorboard allows you to brace your feet, which Keep both hands on the steering wheel. Do not helps you keep your body in the vehicle in the hold the steeering wheel with your thumbs inside the rim. Keep your palms on the outside of the event of an accident or rollover.
Page 80: Learning To Operate Your Vehicle
LEARNING TO OPERATE YOUR VEHICLE Personal protective equipment 1. Approved motorcycle helmet 2. Eye protection 3. Long-sleeved shirt or jacket 4. Gloves 5. Long pants 6. Over-the-ankle boots 7-12...
Page 81: Practice For New Users
Both driver and passenger should wear the follow- Wear eye protection when operation or riding the ing to reduce risk of injury in an accident: vehicle to reduce the risk of a serious accident or Approved motorcycle helmet that fits properly injury.
Page 82: Getting Ready To Ride
Getting ready to ride Perform the Pre-Operation Checks on pages 5- 1_5-11. Follow the instructions starting on pages 6-2_6-3 to start the engine. Become familiar with the way the vehicle feels in low and high ranges, first in two-wheel drive(2WD) and then in four-wheel drive (4WD) and four-wheel drive with the differential locked (DIFF.LOCK).
Page 83: Turning
If you feel the YXQUAD X begin to slide sideways or fishtail during a turn, steer into the direction of the slide, if possible, and gradually let off the accel- erator pedal to regain directional control and avoid rollover.
Page 84: Braking
Engine compression braking is designed to as- Avoid higher speeds and sudden or hard accelera- sist you when operation your YXQUAD X off-road. tion until you are thoroughly familiar with the op- With this feature, the engine helps slow the ve- eration of your vehicle.
Page 85: Leaving The Vehicle
Leaving the vehilce Parking on a flat area Do not get out of the vehicle while the engine is When parking on a flat area, stop the engine and running and the drive select lever is in any gear. shift the drive select lever into the neutral position. There is a risk of injury because: Apply the parking brake to help prevent the ve- Children or others may accidentally press the...
Page 86: Loading
Vehicle loading can affect handling. See “Loading” eration the vehicle. on page 6-9_6-11. The YXQUAD X has higher ground clearance and other features to handle rugged terrain, and as a result, can overturn in situations where some ve- hicles may not. Abrupt maneuvers or aggressive driving can cause loss of control, including rollovers-even on flat, open areas.
Page 87: Hills
If crossing a hill is unavoidable, drive slowly. Turn downhill immediately if you feel the vehicle may tip. If you think or feel the YXQUAD X may tip or roll: Brace yourself by pressing your feet firmly on the floorboards and keep a firm grip on the steer- ing wheel or handholds.
Page 88: Uphill
Uphill Slow down when you reach the crest of the hill if Do not attempt to climb hills until you have mas- you cannot see clearly what is on the other side- tered basic maneuvers on flat ground. Drive straight there could be another person, and obstacle, or a up hills, and avoid crossing the side of a hill, which sharp drop-off.
Page 89: Downhill
Downhill If you are sliding or skidding, try to steer in the Check the terrain carefully before going downhill. direction the vehicle is sliding, to regain control. When possible, choose a path that lets you drive For example, if you feel the back of the vehicle your vehicle straight downhill.
Page 90: Rough Terrain
Rough terrain Water If you must cross shallow, slow-moving water up Operation over rough terrain should be done with caution. to the depth of the vehicle’s floorboards, choose Look for and avoid obstacles that could cause your path carefully to avoid sharp drop-offs, large damage to the vehicle or could lead to a rollover rocks, or slippery surfaces that could cause the or accident.
Page 91: Loose Terrain/Slippery Terrain
To avoid loss of control, slow down and put the of the air filter case, the V-belt cooling YXQUAD X in 4WD before driving on a slippery sur- duct check hose, the drive select lever face and plan your path to avoide making abrupt box check hose and the V-belt case maneuvers.
Page 92: Brush Or Wooded Areas
Brush or wooded areas Encountering obstacles When operating in areas with brush or trees, watch If you cannot go around an obstacle, such as a carefully on both sides and above the vehicle for fallen tree or a ditch, stop the vehicle where it is obstacles such as branches that the vehicle might safe to do so.
Page 93: Periodic Maintenance And Adjustment
PERIODIC MAINTENANCE AND ADJUSTMENT Turn off the engine when performing m a i n t e n a n c e u n l e s s o t h e r w i s e Periodic inspection, adjustment, and lubrication specificed.
Page 94: Owner's Manual And Tool Kit
Owner’s manual and tool kit The service information included in this manual is intended to provide you, the owner, with the nec- You are recommended to put this owner’s manaul essary information for completing your own pre- in the vinyl bag. Put the owner’s tool kit and tire ventive maintenance and minor repairs.
Page 95 If you do not have a torque wrench available during a service operation requiring one, take your ve- hicle to a dealer to check the torque settings and adjust them as necessary.
Page 96: Periodic Maintenance Chart For The Emission Control System
Periodic maintenance chart for the emission control system For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. For vehicles equipped with an odometer or an hour meter, follow the km(mi) or hours maintenance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
Page 97: General Mainternance And Lubrication Chart
General maintenance and lubrication chart INITAIL EVERY month Whichever 2,400 4,800 1,200 2,400 ITEM ROUTINE comes first (1,500) (3,000) (mi) (200) (750) (1,500) hours Check coolant leakage Cooling Repair if necessary Replace coolant every 24 months Clean Every 20-40 hours Air filter element Replace if necessary (More often in wet or dusty areas.)
Page 98: Fitting And Fasteners
INITAIL EVERY month Whichever 2,400 4,800 1,200 2,400 ITEM ROUTINE comes first (1,500) (3,000) (mi) (200) (750) (1,500) hours Check bearing assemblies ofr looseness/damage Wheel bearings Replace if damaged Front and rear Check operation and for leakage suspension Correct if necessary Check operation and for looseness Steering system Replace if damaged...
Page 99: Hood
Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 2. Hood 1. Latch(x2)
Page 100 NOTICE To close Make sure that all cables and wires Lower the hood slowly to its original positon, and are in place when closing the hood. then hook the hood latches. Secure projections Do not drive the vehicle with the (1) on the rear of the hood into slots (2) on the hood open, unlatched, or removed.
Page 101: Console
Console To install 1. Place the console in its original position To remove 2. Install the parking brake lever boot. 1. Remove the seats. (See page 4-16_4-17 for 3. Install the seats. seat removal and installation procedures) NOTICE 2. Remove the parking brake lever boot. Be sure to position the seat belt 3.
Page 102: Engine Oil And Oil Filter Cartridge
Engine oil and oil filter cartridge Check engine oil level before each operation. In addition, change the oil and the oil filter cartridge at the intervals specified in the periodic mainte- nance and lubrication chart. To check the engine oil level ①...
Page 103 5. Insert the dipstick completely into the oil filler hole, and then remove it again to check the oil level. The engine oil should be between the mini- mum and maximum level marks. 1. Maximum level mark 2. Minumum level mark 6.
Page 104 To change the engine oil (with or with- out oil filter cartridge replacement) 1. Park the vehicle on a level surface. 2. Remove the console. (See page 8-9 for con- sole removal and installation procedures.) ① 3. Start the engine, warm it up for several minutes, and then turn off.
Page 105 7. Remove the oil filter cartridge with an oil filter wrench. An oil filter wrench is available from a dealer. Make sure that the O-ring is removed together with the oil filter cartridge. If the O-ring remains attached to the crankcase, oil leakage may occur.
Page 106 ① 12. Refill with the specified amount of recom- mended engine oil, and then insert the dipstick completely into the oil filler hole. NOTICE Be sure to wipe off spill oil on any parts after the engine and exhaust system have cooled down.
Page 107 NOTICE 13. Start the engine, and then let it idle for several In order to prevent clutch slippage ( minutes while checking it for oil leakage. If oil is since the engine oil also lubricates leaking, immediately turn the engine off and check the clutch), do not mix any chemical for the cause.
Page 108: Final Gear Oil
Final gear oil 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to Checking the final gear oil lever raise it to the correct level. 1. Park the vehicle on a level surface. NOTICE 2.
Page 109 Changing the final gear oil 3. Place a container under the final gear case 1. Park the vehicle on a level surface. to collect the used oil. 2. Remove the final gear case guard by remov- 4. Remove the oil filler bolt and the drain bolt to ing the bolts and the collars.
Page 110 6. Refill with the recommended final gear oil up 9. Install the final gear case guard by installing to the brim of the filler hole. the bolts and the collars, and then tightening NOTICE teh bolts to the specified torque. Be sure to no foreign material enters Tightening torque the final gear case.
Page 111: Differential Gear Oil
Differential gear oil 3. Reinstall tire differential gear oil filler bolt, and Checking the differential gear oil level then tighten it to the specified torque. 1. Park the vehicle on a level surface. Tightening torque 2. Remove the differential gear oil filler bolt and Differential gear oil filler bolt check the oil level.
Page 112 3. Place a container under the differential gear 6. Refill the differential gear case with the rec- case to collect the used oil. ommended oil. 4. Remove the differential gear oil filler bolt and NOTICE differential gear oil drain bolt to drain the oil. Be sure to no foreign material enters the final gear case.
Page 113: Coolant
9. Install the differential gear case guard by in- stalling the bolts and the collars, and then tight- ① ening the bolts to the specified torque ② FULL Tightening torque Differential gear case graud bolt 7 Nm (0.7 m-kgf, 5.1 ft-lbf) ③...
Page 114 Changing the coolant The coolant must be changed by a dealer at the intervals specified in the periodic maintenance and lubrication chart. Adding water instead of coolant lowers the anti- freeze content of the coolant. If water is used in- stead of coolant, have a dealer check the anti- freeze content of the coolant as soon as possible.
Page 115: Axle Boots
Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a dealer. ① ① 1. Rear axle boot (x2 each side) ① ① 1. Front axle boot (x2 each side) 8-23...
Page 116: Spark Plug Inspection
Spark plug inspection Removal 1. Remove the console. (See page 8-9 for con- sole removal and installation procedures.) 2. Remove the spark plug cap. ① ① 1. Spark plug Wrench 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.
Page 117 Inspection Installation The spark plug is an important engine component 1. Measure the electrode gap with a wire thick- and is easy to inspect. The condition of the spark ness gauge and, if necessary, adjust the gap plug can indicate the condition of the engine. to specification.
Page 118: Cleaning The Air Filter Element
Cleaning the air filter element 3. Install the spark plug and tighten it to the specified torque. If a torque wrench is not avail- There is a check hose at the bottom of the air filter able when you are installing the spark plug, a case and at the bottom of the air duct under the good estimate of the correct torque is one-quarter case.
Page 119 1. Open the hood. ( See pages 8-7_8-8 for hood opening and closing procedures.) 2. Remove the air intake duct shroud by remov- ing the quick fastener screws. 1. Air filter case check hose 1. Quick fastener screw (x2) 2. Air intake duct shroud 8-27...
Page 120 3. Remove the air filter case cover by unhook- 4. Remove the air filter element. ing the holders. 1. Air filter element 1. Air filter case cover holder(x5) 2. Air filter case cover 8-28...
Page 121 5. Remove the sponge material from its frame. 6. Wash the sponge material gently but thor- oughly in parts cleaning solvent. Using gasoline or other flammable sol- vents to clean the air filter element can cause a fire or explosion, which could lead to serious injury.
Page 122 8. Wash the sponge material in warm soapy 14. Insert the projections on the air filter case water to remove remaining solvent, then rinse cover into the holder on the air filter case, and thoroughly with plain warm water. then install the air filter case cover by hooking 9.
Page 123: Drive Select Lever Box Check Hose
Drive select lever box check hose The air filter element should be cleaned every 20- 40 hours. It should be cleaned and lubricated more The drive select lever box check hose is located often if the vehicle is operated in extremely dusty under the console.
Page 124: V-Belt Case Drain Plug
V-belt case drain plug The V-belt case drain plug is located under the driver seat. ( See pages 4-16_4-17 for seat removal and installation procedures.) After riding in water deep enough to allow water to enter the V-blet case, remove the drain plug to drain any water from the case.
Page 125: Cleaning The Spark Arrester
Cleaning the spark arrester 2. Remove the tailpipe by pulling it out of the muffler, and then remove the gasket. Hot exhaust system may cause burns. 3. Tap the tailpipe lightly, and then use a wire To avoid burns or fires, make sure that brush to remove any carbon deposits from the the engine is stopped and the exhaust spark arrester portion of the tailpipe and inside...
Page 126: Valve Clearance
Brakes Tightening torque Replacement of brake components requires pro- Tailpipe bolt: fessional knowledge. Brake service should be per- 10 Nm (1.0 m-kgf, 7.2 ft-lbf) formed by a dealer Valve clearance Operating with improperly serviced or The correct valve clearance changes with use, re- adjusted brakes could lead to a loss in sulting in improper fuel/air supply or engine noise.
Page 127: Checking The Parking Brake Pads
Checking the parking brake pads The wheels need to be removed to check the brake Each brake pad is provided with two wear indica- pads. (See pages 8-43_8-46 for wheel removal and tor grooves, which allow you to check the brake installation procedures.) pad wear without having to disassemble the brake.
Page 128 Checking the brake fluid level The brake fluid reservoir is located under the hood. ( See pages 8-7_8-8 for hood opening and closing ① procedures.) Observe these precautions: When checking the fluid level, make sure the top of the brake fluid reservoir is level. Use only the recommended quality brake fluid.
Page 129: Brake Fluid Replacement
Checking the brake pedal Brake fluid may deteriorate painted surfaces Have a dealer check the brakes at the intervals or plastic parts. Always clean up spilled fluid specified in the periodic maintenance and lubrica- immediately. tion chart. There should be no free play in the brake Have a dealer inspect the brake system if the pedal.
Page 130: Parking Brake Lever Free Play Adjustment
Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary. 1. Shift the drive select lever into low gear “L”. 2. Remove the seats. (See pages 4-16_4-17 for seat removal and installation procedures.) 3.
Page 131: Brake Light Switch Adjustment
Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Open the hood. ( See pages 8-7_8-8 for hood opening and closing procedures.) 2.
Page 132: Cable Inspection And Lubrication
Cable inspection and lubrication D a m a g e d c a b l e s c o u l d r e s t r i c t operation, which may cause an accident or injury. Inspect control cables fre- quently and replace damaged cables.
Page 133: Brake Pedal And Accelerator Pedal Lubrication
Brake pedal and accelerator pedal Rear knuckle upper and lower pivot Lubrication Lubrication Lubricate the pivoting parts. 1. Remove the lower arm protector by removing the bolts. Recommended lubricant: Lithium-soap-based grease 1. Bolt (x3) 2. Lower arm protector 8-41...
Page 134 2. Lubricate the knuckle upper and lower piovts 2. Install the lower arm protector by installing with a grease gun the bolts and tightening them to the specified torque Tightening torque Lower arm protector: 7 Nm (0.7 m-kgf, 5.1 ft-lbf) Recommended lubricant: Lithium-soap-based grease 8-42...
Page 135: Steering Shaft Lubricaion
Steering shaft lubrication Wheel removal Lubricate the pivot points. 1. Loosen the wheel nuts. 2. Elevate the vehicle and place a suitable stand Recommended lubricant: under the frame. Lithium-soap-based grease 3. Remove the nuts from the wheel 4. Remove the wheel 1.
Page 136: Tire Replacement
Always use the same size and type of tires rec- ommended in this owner’s manual. The tires that came with your YXQUAD X were designed to match the performance capabilities and to provide the best combination of handing, braking, and comfort. It is best to replace all four tires at the same time.
Page 137: Wheel Installation
2. Lower the vehicle so that the wheel is on the 1. Arrow mark ground. 3. Tighten the wheel nuts to the specified torque. Do not reverse the rims on the YXQUAD X to widen the track width. Installing wheels improperly increases the risk of wheel failure and accidents.
Page 139: Battery Maintenance
Battery maintenance Avoid battery contact with skin, eyes, 1. If the vehicle will not be used for a month or clothing. Shield eyes when working or longer, remove the battery and store it in a near batteries. Keep out of reach of cool, dark place.
Page 140 ① ② 1. Negative battery lead (black) 2. Positive battery lead(red) 8-48...
Page 141: Fuse Replacement
Fuse replacement Turn the key to “OFF” and turn off the electrical The main fuse, the fuel injection system fuse, and circuit in question. the fuse box are located under the hood. (See NOTICE pages 8-7_8-8 for hood opening and closing To prevent accidental short-circuiting, procedures.) turn off the main switch when check-...
Page 142 Specified fuses: Main fuse: 40.0 A 10.0 A Fuel injection system fuse: Headlight fuse: 15.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Signaling system fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A 25.0 A Radiator fan fuse Backup fuse: 10.0 A ②...
Page 143: Replacing A Headlight Bulb
Replacing a headlight bulb 3. Remove the headlight bulb holder by pulling it in and turning it counterclockwise If a headlight bulb burns out, replace it as follows. 1. Lift the hood up. ( See pages 8-7_8-8 for hood opening and closing procedures) ①...
Page 144 4. Wait for the headlight bulb to cool before 7. Reinstall the bulb holder by pushing it in and touching or removing it. Remove the bulb by turning it clockwise. pulling it out. Reinstall the bulb holder cover and the cover at 6.
Page 145: Headling Beam Adjustment
Headlight beam adjustment NOTICE It is advisable to have a dealer make this adjustment. To raise the beam or to lower the beam, turn the adjusting screw. ① 1. Headlight beam adjusting screw 8-53...
Page 146 8-54...
Page 147 2. Lift the cargo bed up. (See pages 4-20_4-21 for 7. Reinstall the bulb holder (together with the bulb) cargo bed lifting and lowering procedures.) by turning it clockwise. 3. Remove the panel (panel A or B) 8. Install the panel. 4.
Page 148: Troubleshooting
Troubleshooting When checking the fuel system, do not Although vehicles receive an inspection before smoke and make sure there are no open shipment from the factory, trouble may occur dur- flames or sparks in the area, including ing operation. Any problem in the fuel, compression, pilot lights from water heaters or or ignition systems can cause poor starting and furnaces.
Page 149: Troubleshooting Charts
Troubleshooting charts Starting problems or poor engine performance 8-57...
Page 150 Engine overheating Wait for the engine to cool before removing the radiator cap. If the engine is not cool when removing the radiator cap, hot fluid and steam could blow out under pressure and burn you. Place a thick rag over the cap and remove the cap slowly to allow any remaining pressure to escape.
Page 151: Cleaning And Storage
CLEANING AND STORAGE 3. Rinse the dirt and degrease off with a garden A. Cleaning hose. Use only enough pressure to do the job. Frequent, thorough cleaning of your vehicle will not Test the brakes after washing. Apply the only enhance its appearance but will improve its brakes several times at slow speeds to general performance and extend the useful life of let friction dr y out the linings.
Page 152: Storage
B. Storage 4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, Long term storage ( 60 days or more) of your ve- detergent-type soap. An old toothbrush or bottle hicle will require some preventive procedures to brush is handy for hard-to-get-at places.
Page 153 2. Remove the spark plug, pour about one 7. Remove the battery and charge it. Store it tablespoon of SAE 10W-40 or 20W-50 motor in a dry place and recharge if once a month. oil in the spark plug hole and reinstall the spark Do not store the battery in an excessively plug.
Page 154: Specifications
SPECIFICATIONS ENGINE 493cc,1-cylinder,4 stroke,4 valve,SOHC,water/oil cooled Type Bore x Stroke 87.5mm x 82mm Compression Ratio 10.3:1 Rated power 25kw/6000rpm Rated.torque 45Nm/5000rpm Carburetion BSR36 Ignition Starting Electric starter Transmission L-H-N-R Drive Train Shaft drive CHASSIS Suspension/Front Independent double swing arm Suspension/Rear Independent double swing arm Brakes/Front Dual ventilated hydraulic disc...