After 1,500 hard off-road miles, we evaluated how our long-travel Yamaha YXZ1000R build held up—and which modifications made the biggest difference.
By Cody Hooper
Most UTV project builds happen quickly. A new machine arrives, aftermarket partners help transform it, and after a season of testing, it is often replaced by the next project. We chose to do something different with this 2016 Yamaha YXZ1000R.
This YXZ was especially meaningful because it was sold to us by the late Art Wood before his passing. Art was an important part of the UTV industry and is fondly remembered for his friendly demeanor and constant willingness to help others.
We purchased the machine when factory loan units were unavailable. Over the following year and a half, it evolved into our version of an all-around play and chase car. We drove it more than 1,500 hard miles through dunes, desert and rocky terrain to answer a practical question: How does an extensively modified, high-dollar Yamaha YXZ1000R build hold up under real recreational use?
The project began with help from SDR Motorsports. With only 80 miles on the odometer, Tim Berendes and his crew stripped the YXZ down to its frame and began installing the fabrication, suspension, wiring and accessories needed to create a versatile long-term build.
The long-travel Yamaha YXZ1000R testing in the dunes.
Building the Chassis and Suspension
SDR Motorsports of Corona, California, performed the cage work. This was one of the company’s early YXZ1000R cages and used 1.75-inch DOM tubing for the main structure. It incorporated a rear bumper, full aluminum roof with a light-bar pocket and a 1.5-inch DOM V-shaped intrusion bar across the windshield area.
SDR also installed an HCR Racing Dual-Sport long-travel suspension kit. Its plated, slot-and-tab boxed control arms were engineered to withstand demanding off-road use. We powder-coated the suspension components and cage in a factory-style Yamaha blue to give the entire build a cohesive appearance.
The HCR Dual-Sport kit widened the YXZ1000R by four inches per side, producing an approximately 72-inch-wide stance. That additional track width noticeably increased stability in corners. King 2.5-inch internal-bypass shocks complemented the long-travel suspension with a compliant ride over chop and useful bottoming resistance through deep holes and hard G-outs.
The kit also included a replacement front shock tower designed to improve shock positioning and suspension geometry. HCR supplied extended 300M axle shafts, which we used with the factory CV joints. The axle and CV combination completed more than 1,500 hard miles without a failure.
Once the suspension was installed, SDR began wiring the numerous electrical accessories. The shop used a dedicated fuse block and custom wire looms to keep the installation organized and serviceable.
The Yamaha YXZ1000R build in Johnson Valley.
Electrical, Communications and Lighting
The electrical system supported an SSV Works five-speaker stereo, Rugged Radios communications equipment, Lowrance GPS, KC HiLiTES lighting, a fresh-air system and six-foot Tribal Whips LED whips.
The SSV Works system used four custom fiberglass enclosures for its 6.5-inch speakers and a fiberglass enclosure for a 10-inch subwoofer behind the passenger seat. An MRB2 Bluetooth controller eliminated the need for a conventional head unit. Despite rain, repeated wash cycles and heavy silt exposure, the stereo system did not suffer a failure during our test period.
Our Rugged Radios RRP660+ intercom provided clear communication between the driver and passenger. The accompanying two-way radio made group rides easier by allowing cars to communicate through dust and along tight trails.
We also installed a Rugged M3 variable-speed fresh-air pumper. Closing a helmet visor and connecting the filtered-air hose was a significant improvement in dusty conditions, though the system required helmets equipped with compatible air inlets.
The factory headlights provided adequate visibility at modest trail speeds, but we wanted considerably more output for faster night driving and dune use. A 40-inch KC Flex LED light bar went above the windshield, while pairs of Flex pods on the A-pillars were aimed outward to improve peripheral visibility.
KC Cyclone lights illuminated the interior and underbody. An amber rear chase light improved the visibility of the YXZ1000R from behind, which was useful because the original machine had only one low-mounted taillight.
The tall Tribal Whips Aurora LED whips made the car easy to spot and offered multiple programmable color combinations. Their single-pin mounts also made them easy to remove when necessary.
The completed YXZ1000R was equipped for dunes, desert and technical trails.
Seats, Storage and Accessories
Simpson supplied a pair of Vortex seats. Their cutaway hip bolsters made it easier to enter and exit the car while still providing good occupant support. The seats survived hundreds of hours of use, washing and sun exposure without giving us trouble. Custom door bags added storage inside the factory Yamaha doors.
Assault Industries supplied many of the smaller components that made the car more functional. Its 1.75-inch aluminum clamps supported accessories throughout the cage; we ultimately used at least 16 of them.
Assault also fabricated a removable aluminum roof rack with interchangeable, laser-cut side plates. Additional equipment included sun visors, B2 Bomber side mirrors, a center mirror, billet short shifter, Warthog front bumper, quick-release fire extinguisher, four-point harnesses, tie rods and upgraded sway-bar links.
A factory Yamaha cargo box provided enclosed storage in the rear bed. Because the lighting, stereo, GPS, radios and air system placed considerable demand on the electrical system, we installed the GYTR dual-battery and alternator kits. A smart relay helped keep the auxiliary battery charged without overcharging it.
Before adding the alternator, the original charging system occasionally left us with a dead battery after long night rides. The manual-transmission YXZ could be bump-started when necessary, but the upgraded charging system was a much better long-term solution.
SDR Motorsports and Assault Industries helped make the YXZ1000R more capable and practical.
Graphics and Exterior Appearance
The YXZ1000R wore two different graphic combinations during the project, both produced by Wolf Designs. The first used a red, white and blue theme that complemented the factory bodywork. The second combined a dark-blue fade with bright yellow and orange honeycomb details.
Both wraps held up well in harsh desert conditions. Installation required patience because of the YXZ1000R’s numerous body panels and contours, but the finished graphics gave the project a distinctive appearance.
The modified Yamaha YXZ1000R roosting through the dunes.
Engine, Exhaust and GYTR Gearing
The naturally aspirated YXZ1000R was already an entertaining performer, but we wanted sharper response. Trinity Racing supplied a Stage 5 single-muffler exhaust with stainless-steel and aluminum construction. Its header fit cleanly around the YXZ’s rear-mounted engine, and installation was straightforward once the bulky factory muffler was removed.
Trinity also supplied a plug-in EFI tuner with a three-button LED interface. After adjusting the settings to suit our combination, the exhaust and fuel tuning made the engine feel substantially stronger than it did with the stock exhaust.
The more important performance change was the gearing. Early YXZ1000R models had a tall first gear, which made slow climbs and uphill starts difficult—especially after fitting larger 30-inch STI Chicane RX tires.
We addressed the issue with Yamaha’s GYTR Torque Assist Gear kit. The internal transmission kit reduced first gear by approximately 70 percent and the other four gears by approximately 30 percent. A Yamaha dealership installed the kit and upgraded the clutch while the transmission was apart.
The result transformed the machine. First gear became far more manageable for crawling and hill starts, while the closer ratios made it easier to keep the high-revving engine in its effective power range. For more detail on how the system performed, see our YXZ1000R GYTR Torque Assist Gear review.
The eight-ply STI Chicane RX tires provided precise steering, predictable side bite and strong forward traction. We accumulated more than 900 dirt miles on the tires without a structural failure, although we repaired a couple of punctures with plugs. We carried a full-size spare on the roof rack but never needed to install it.
Fine-tuning the King shocks completed the package. The finished setup worked well in the desert, on rocky trails and in the dunes, requiring little more than clicker adjustments when moving between terrain types. The increased ground clearance, 30-inch tires and lower gearing made the YXZ1000R substantially more capable in technical terrain.
The upgraded lighting made the YXZ1000R much more useful after dark.
Reliability After 1,500 Hard Miles
We drove the YXZ1000R in three states and nine different desert areas, covering nearly every type of terrain except deep mud. Its reliability was one of the most impressive parts of the project.
Routine service consisted primarily of checking fasteners, changing the oil and keeping the air filters clean. The machine did suffer a few minor failures. A factory sway-bar link bent into a U-shape after a hard landing in the dunes, so we replaced the links with heavier heim-joint units from Assault Industries. We also damaged two factory skid plates beneath the rear differential before fabricating a replacement from sheet steel.
Neither problem sidelined the machine or pointed to a fundamental powertrain weakness. The engine, transmission, HCR axles and original CV joints remained reliable throughout the test.
How the Completed YXZ1000R Drove
The defining quality of this build was how well its individual components worked together. The HCR suspension and King shocks increased speed and control through rough terrain. The GYTR gearing made technical driving easier. The SDR cage and wiring formed a sound foundation, while the Rugged Radios communications, KC lighting and other accessories made long rides more enjoyable.
The YXZ1000R did not produce the acceleration of a contemporary turbocharged UTV, but it delivered a much more mechanical driving experience. Its sequential five-speed transmission, high-revving three-cylinder engine and direct connection between the driver and powertrain required genuine participation.
Miss a shift and the car lost momentum. Stop without using the clutch and the engine stalled. Get the timing right, however, and few UTVs offered the same satisfaction. That involvement is one reason the YXZ1000R remains distinctive in sport UTV history.
Readers researching the model can explore the complete Yamaha YXZ1000R history, model changes and review guide. Our original YXZ1000R SS review also explains how Yamaha’s Sport Shift version changed the driving experience.
Driver Opinions
Mark Hooper
Age: 57
Occupation: Contractor and IN2DIRT Media photographer
Experience: Weekend warrior
“I can’t believe how much fun this car is. This suspension sets you up for corners like the car is on rails. It flies perfectly flat. When the nose starts to come down, its precise balance puts just the right amount of load on the front end, so the car is ready to turn before you are.
“I already knew I would love shifting a UTV. There is something genuine about slamming gears in an off-road vehicle. Do I want second or third going into a corner? It is a fun question to ask. You can rev the car to 10,000 rpm, rip out of the corner and hit two-foot chop, and the car just doesn’t care.
“The one issue I had with the stock machine was its tall first gear. I couldn’t trust it in uphill, stop-and-go situations, so we installed the 70/30 gear reduction. It is a completely different machine now and an absolute blast to drive. We are a multibrand UTV family and have driven nearly everything, but nothing gives me the same interactive off-road experience as the Yamaha YXZ.”
Chris Kemp
Age: 53
Occupation: Business owner and desert racer
Experience: BITD Class 1 champion and Trophy Truck driver
“I can’t believe how good these UTVs have become. I owned a Rhino years ago, and it was great for hauling parts between pits, but it wasn’t a sporty machine. This YXZ is sharp. The turn-in feels good, and the car goes where you point it every time.
“The engine is a blast. It revs and revs. There isn’t a lot happening low in the rpm range, but once it gets above 7,000 rpm, it moves well. The suspension is plush through chop while still offering good bottoming resistance. I didn’t expect it to work through rough terrain as well as it does. It is comfortable enough to spend all day on the trail.”
Yamaha YXZ1000R Build Parts List
- Cage: SDR Motorsports
- Installation and wiring: SDR Motorsports
- Suspension: HCR Dual-Sport long-travel kit
- Shocks: King 2.5-inch internal-bypass shocks
- Axles: HCR 300M shafts with factory CV joints
- Wheels: 15-inch STI HD5 beadlocks
- Tires: 30x10R15 STI Chicane RX
- Brakes: Stock
- Front bumper: Assault Industries Warthog
- Rear bumper: SDR Motorsports
- Doors and body: Stock
- Graphics: Wolf Designs
- Rear storage: GYTR Yamaha cargo box
- LED whips: Tribal Whips Aurora
- Exhaust: Trinity Racing Stage 5
- Fuel tuning: Trinity Racing EFI tuner
- Stereo: SSV Works five-speaker amplified system with subwoofer
- Communications: Rugged Radios RM-25R radio and RRP660+ intercom
- Fresh-air system: Rugged Radios M3
- Seats: Simpson Vortex
- Harnesses: Assault Industries H-style
- Mirrors: Assault Industries B2 Bomber and Stealth rearview
- Fire extinguisher: Assault Industries quick-release kit
- Visors: Assault Industries
- Roof rack: Custom Assault Industries rack
- Shifter: Assault Industries billet Pro shifter
- Transmission: GYTR Torque Assist 70/30 gear kit and upgraded clutch
- Engine: Stock internally
- Roof light: 40-inch KC Flex LED light bar
- A-pillar lights: KC Flex LED pods
- Interior and underbody lighting: KC Cyclone LEDs
- Rear chase light: KC C3 amber LED
- Charging system: GYTR alternator and dual-battery kits
- GPS: Lowrance HDS-5
Editor’s note: This article documents a build completed and tested during the original 2016–2017 project period. Individual products, prices and availability may have changed since the original test.
Yamaha YXZ1000R Build Gallery
