2004 YAMAHA GRIZZLY 125 check oil

LOCATION OF THE WARNING AND
SPECIFICATION LABELS .......................1-1
SAFETY INFORMATION .........................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................3-1
Identification number records ...............3-3
Key identification number .....................3-5
Vehicle identification number ...............3-5
Model label ...........................................3-7
CONTROL FUNCTIONS..........................4-1
Main switch ...........................................4-1
Indicator lights ......................................4-3
Handlebar switches ..............................4-5Throttle lever ......................................4-11
Speed limiter ......................................4-13
Front brake lever ................................4-15
Rear brake lever .................................4-15
Parking brake .....................................4-17
Drive select lever ................................4-19
Fuel tank cap ......................................4-19
Fuel cock ............................................4-21
Starter (choke) ....................................4-23
Seat ....................................................4-25
Front carrier ........................................4-27
Rear carrier ........................................4-27
PRE-OPERATION CHECKS ...................5-1
Front and rear brakes ...........................5-5
Fuel ......................................................5-7
Engine and final transmission oil ........5-11
EBU00015
CONTENTS
1
2
3
4
5
1C5-9-60-01 11/12/03 7:26 PM Page 12

PERIODIC MAINTENANCE AND
ADJUSTMENT .........................................8-1
Owner’s manual and tool kit .................8-3
Periodic maintenance/Lubrication ........8-7
Engine oil ............................................8-13
Final transmission oil ..........................8-21
Spark plug inspection .........................8-27
Engine air filter element and V-belt
case air filter element cleaning .........8-31
Idle speed adjustment ........................8-43
Valve clearance adjustment ...............8-45
Throttle lever adjustment ....................8-45
Front and rear brake shoe
inspection .........................................8-47
Front brake lever free play
adjustment ........................................8-49
Rear brake adjustment .......................8-59
Drive chain slack check ......................8-61
Drive chain slack adjustment ..............8-63Lubricating and drive chain ................8-67
Draining the V-belt compartment ........8-69
Cable inspection and lubrication ........8-71
Brake lever lubrication ........................8-73
Knuckle shaft, lower arms and
steering shaft lubrication ..................8-73
Wheel removal ...................................8-75
Wheel installation ...............................8-75
Battery ................................................8-77
Replenishing a battery fluid ................8-81
Fuse replacement ...............................8-85
Replacing the headlight bulb ..............8-87
Tail/brake light bulb replacement .......8-91
Headlight beam adjustment ................8-93
Troubleshooting ..................................8-95
Troubleshooting chart .........................8-998
1C5-9-60-01 11/12/03 7:26 PM Page 14

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes• Check operation, condition and free play. 5-5 – 5-7,
• Adjust if necessary. 8-47 – 8-59
Fuel • Check fuel level.
• Fill with fuel if necessary.5-7 – 5-11
Engine oil and• Check oil level. 5-11 – 5-15,
final transmission oil• Fill with oil if necessary. 8-13 – 8-25
Drive chain• Check chain slack and condition.
5-15, 8-61 – 8-69
• Adjust if necessary.
Throttle• Check for proper throttle cable operation. 5-15
Wheels and tires• Check tire pressure, wear and damage. 5-19 – 5-25, 8-75
Fittings and fasteners• Check all fittings and fasteners. 5-15
Battery• Check fluid level.
5-17, 8-77 – 8-83
• Fill with distilled water if necessary.
Lights and switches• Check for proper operation. 5-17, 8-87 – 8-93
1C5-9-60-05 15/12/03 7:59 PM Page 2

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
INITIAL EVERY
ITEM ROUTINE
13661
monthmonths months monthsyear
Valves*• Check valve clearance.
1111
• Adjust if necessary.
• Check condition.
Spark plug• Adjust gap and clean.11111
• Replace if necessary.
Air filter element
• Clean. Every 20–40 hours
(for engine and V-belt
• Replace if necessary. (more often in wet or dusty areas)
case)
Carburetor*• Check idle speed/starter operation.
1111
• Adjust if necessary.
Cylinder head cover• Check breather hose for cracks or damage.
111
breather system*• Replace if necessary.
• Check leakage.
Exhaust system*• Retighten if necessary.111
• Replace gasket if necessary.
Fuel line*• Check fuel hose for cracks or damage.
111
• Replace if necessary.
Engine oil• Replace (warm engine before draining).1111
Oil strainer*• Clean.
111
• Replace if necessary.
Drive chain• Check and adjust slack/alignment/clean/lube.11111
Final transmission oil• Check oil level/oil leakage.
11
• Replace every 12 months.
1C5-9-60-08 9/12/03 8:38 PM Page 8-8

8-13
EBU14900
Engine oil
The engine oil level should be checked before
each ride. In addition, the oil must be changed
at the intervals specified in the periodic mainte-
nance and lubrication chart.
Engine oil level measurement
1. Place the machine on a level surface.
2. Warm up the engine for several minutes and
stop it.
3. Wait a few minutes until the oil level settles,
remove the oil filler cap, wipe off the dipstick
clean. Insert the dipstick in the filler hole
without screwing it in.
NOTE:
Wait a few minutes until the oil level settles
before checking.
4. Remove the dipstick and inspect the oil
level.
5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
add oil to raise it to the proper level.
qw
e
1. Dipstick
2. Maximum level mark 3. Minimum level mark
1. Jauge
2. Repère de niveau maximum 3. Repère de niveau minimum
1. Varilla de medición
2. Marca de máximo 3. Marca de mínimo
1C5-9-60-08 9/12/03 8:38 PM Page 8-14

8-19
cC
Be sure no foreign material enters the
crankcase.
9. Warm up the engine for several minutes at
idle speed. Check for oil leakage while
warming up.
cC
If oil leakage is found, stop the engine imme-
diately and check for the cause.
Recommended oil:
See page 10-2.
Oil quantity:
Periodic oil change
1.25 L
1C5-9-60-08 9/12/03 8:38 PM Page 8-20

8-21
EBU14912
Final transmission oil
The final transmission case must be checked for
oil leakage before each ride. If any leakage is
found, have a Yamaha dealer check and repair
the machine. In addition, the final transmission
oil must be changed at the intervals specified in
the periodic maintenance and lubrication chart.
Final transmission oil measurement
1. Place the machine on a level surface.
2. Remove the screw and check the oil level. It
should be up to the brim of the hole. If the
oil level is low, remove the oil filler bolt, and
then add sufficient oil of the recommended
type to raise it to the proper level.
3. Install the screw and oil filler bolt, and then
tighten them to their specified torques.we
q
q
1. Screw 2. Brim 3. Correct oil level
1. Vis 2. Bord 3. Niveau d’huile correct
1. Tornillo 2. Borde 3. Nivel correcto de aceite
1. Oil filler bolt
1. Boulon de remplissage d’huile
1. Tapón de llenado de aceite
Tightening torque:
Screw:
16 Nm (1.6 m0kgf)
Oil filler bolt:
23 Nm (2.3 m0kgf)
1C5-9-60-08 9/12/03 8:38 PM Page 8-22

8-31
EBU14840
Engine air filter element and V-belt case air
filter element cleaning
Both air filter elements should be cleaned at the
specified intervals in the periodic maintenance
chart.
Engine air filter element
NOTE:
There is a check hose at the bottom of the air fil-
ter case. If dust or water collects in this hose,
empty the hose and clean the air filter element
and air filter case.
1. Remove the seat.
2. Remove the breather hose, and then loosen
the clamp screw.
3. Remove the air filter case cover by remov-
ing the screws.
q
1
3
4
5
2
2
2
2
1. Check hose1. Flexible de contrôle1. Manguito de comprobación
1. Air filter case cover 2. Screw (
× 4)
3. Breather hose 4. Clamp 5. Clamp screw
1. Cache du boîtier de filtre à air 2.Vis (× 4)
2. Reniflard 3. Bride 5. Vis de coiler
1.Tapa de la caja del filtro de aire2. Tornillo (× 4)
3. Tubo de ventilación 4. Abrazadera 5. Tornillo de sujeción
1C5-9-60-08 9/12/03 8:38 PM Page 8-32