2005 YAMAHA GRIZZLY 125 engine

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
1C5-9-61-01 9/4/04 8:48 PM Page 12

Chain ..................................................5-15
Throttle lever ......................................5-15
Fittings and fasteners .........................5-15
Lights ..................................................5-17
Switches .............................................5-17
Battery ................................................5-17
Tires ...................................................5-19
How to measure tire pressure ............5-23
Tire wear limit .....................................5-25
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine ......................6-11
Warming up ........................................6-11
Drive select lever operation and reverse
driving ...............................................6-13
Engine break-in ..................................6-19Parking ...............................................6-23
Parking on a slope ..............................6-25
Accessories and loading ....................6-27
Riding Your ATV ......................................7-1
Getting to know your ATV.....................7-3
Ride with care and good
judgement ...........................................7-5
Be careful where you ride ...................7-29
Turning your ATV ...............................7-41
Climbing uphill ....................................7-45
Riding downhill ...................................7-57
Crossing a slope .................................7-61
Crossing through shallow water .........7-65
Riding over rough terrain ....................7-69
Sliding and skidding ...........................7-71
What to do if .......................................7-75
What to do ..........................................7-751
6
7
1C5-9-61-01 9/4/04 8:48 PM Page 13

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
1C5-9-61-01 9/4/04 8:48 PM Page 14

2-1
EBU00221
AN ATV IS NOT A TOY AND CAN BE HAZ-
ARDOUS TO OPERATE. An ATV handles dif-
ferently from other vehicles including motorcy-
cles and cars. A collision or rollover can occur
quickly, even during routine maneuvers such as
turning and riding on hills or over obstacles, if
you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you
do not follow these instructions:
8Read this manual and all labels carefully and
follow the operating procedures described.
8Never operate an ATV without proper instruc-
tion.
8Always follow the age recommendation:
- A child under 16 years old should never
operate an ATV with engine size greater than
90cc.
qSAFETY INFORMATION
1C5-9-61-02 22/3/04 7:22 PM Page 2

2-15
8Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed
and securely attached. Reduce speed and fol-
low instructions in this manual for carrying
cargo. Allow greater distance for braking.
w
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling. Never
refuel while smoking, or while in the vicinity
of sparks, open flames, or other sources of
ignition such as the pilot lights of water
heaters and clothes dryers. Gasoline can
catch fire and you could be burned.
1C5-9-61-02 22/3/04 7:22 PM Page 16

2-17
When transporting the machine in another
vehicle, be sure it is kept upright and that the
fuel cock is in the “OFF” position. Otherwise,
fuel may leak out of the carburetor or fuel tank.
Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
spills on your skin, wash with soap and
water. If gasoline spills on your clothing,
change your clothes.
w
Always operate your machine in an area with
adequate ventilation. Never start or run the
engine in a closed area. Exhaust fumes are
poisonous and may cause loss of con-
sciousness and death within a short time.
1C5-9-61-02 22/3/04 7:22 PM Page 18

4-1
EBU00040
CONTROL FUNCTIONS
EBU09420
Main switch
Functions of the respective switch positions are
as follows:
ON:
The engine can be started only at this position
and the headlights and taillight come on when
the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
OFF ON
1C5-9-61-04 22/3/04 3:08 PM Page 2

4-5
EBU00053
Handlebar switches
EBU11580
Engine stop switch “ENG. STOP”
Make sure that the engine stop switch is in the
“RUN” position before starting the engine. The
engine stop switch controls ignition and can be
used at all times to stop the engine, especially in
an emergency. The engine will not start or run
when the engine stop switch is turned to “OFF”.
EBU00056
Start switch “START”
The starter motor cranks the engine when this
switch is pushed.
cC
See starting instructions prior to starting
engine (see page 6-3 for details).
w
q
e
1. Engine stop switch “ENG. STOP”
2. Light switch “LIGHTS”
3. Start switch “START”
1. Coupe-circuit du moteur “ENG. STOP”
2. Contacteur d’éclairage “LIGHTS”
3. Contacteur de démarreur “START”
1. Interruptor de paro del motor “ENG. STOP”
2. Interruptor de luces “LIGHTS”
3. Interruptor de arranque “START”
1C5-9-61-04 22/3/04 3:08 PM Page 6