2004 YAMAHA GRIZZLY 125 engine 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

5-11
w
8Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is over-
filled, fuel could spill out due to heat from
the engine or the sun.
8Be careful not to spill fuel, especially on
the engine or exhaust pipe which can
cause a fire and severe injury. Wipe up
any spilled fuel immediately.
8Do not refuel right after the engine has
been running and is still very hot.
8Be sure the fuel tank cap is closed secure-
ly.
EBU11163
Engine and final transmission oil
Make sure the engine and final transmission oil
is at the specified level. Add oil as necessary.
(See page 8-13–8-25.)
1C5-9-60-05 15/12/03 7:59 PM Page 12

5-13
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8Do not use oils with a diesel specification
of “CD” or oils of a higher quality than
specified. In addition, do not use oils
labeled “ENERGY CONSERVING II” or
higher.
8Be sure no foreign material enters the
crankcase.
Recommended engine oil type and quantity:
See page 10-2.
Recommended final transmission oil type
and quantity:
See page 10-2.
1C5-9-60-05 15/12/03 7:59 PM Page 14

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

8-15
cC
Be sure no foreign material enters the
crankcase.
Engine oil replacement and oil filter cleaning
1. Place the machine on a level surface.
2. Warm up the engine for several minutes and
stop it.
3. Place a container under the engine to col-
lect the used oil.
4. Remove the dipstick and drain bolt to drain
the oil.
cC
When removing the drain bolt, the compres-
sion spring, oil strainer and O-ring will fall
out. Take care not to lose these parts.
q
rewq
1. Drain bolt 2. O-ring
3. Compression spring 4. Oil strainer
1. Boulon de vidange 2. Joint torique
3. Ressort de compression 4. Crépine à huile
1. Tapón de drenaje 2. Junta torica
3. Resorte de compresión 4. Taza de aceite
1C5-9-60-08 9/12/03 8:38 PM Page 8-16