2005 YAMAHA GRIZZLY 125 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
1C5-9-61-01 9/4/04 8:48 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
1C5-9-61-01 9/4/04 8:48 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
1C5-9-61-05 22/3/04 5:39 PM Page 2

5
5-2
FBU00113
CONTRÔLES AVANT LE DÉMARRAGE
Contrôler les points suivants avant de mettre le moteur en marche:
DESCRIPTION VÉRIFICATION PAGE
Freins• Contrôler le fonctionnement, l’état et le jeu. 5-6 – 5-8,
• Régler si nécessaire. 8-48 – 8-60
Carburant• Vérifier le niveau de carburant.
• Ajouter du carburant si nécessaire.5-8 – 5-12
Huile moteur/• Contrôler le niveau d’huile. 5-12 – 5-16,
huile de transmission finale• Ajouter de huile si nécessaire. 8-14 – 8-26
Chaîne de transmission• Contrôler la tension et l’état de la chaîne.
5-16, 8-62 – 8-70
• Régler si nécessaire.
Accélélateur• Vérifier le fonctionnement des câbles d’accélérateur. 5-16
Roues et pneus• Vérifier la pression de gonflage des pneus/le voile/
5-20 – 5-26, 8-76
la tension des rayons/les écrous d’axes.
Visserie• Contrôler tours les assemblages et fixations. 5-16
Batterie• Contrôler le niveau du liquide.
5-18, 8-78 – 8-84
• Ajouter avec de l’eau distillée si nécessaire.
Éclairage et contacteurs• Contrôler si le fonctionnement est correct. 5-18, 8-88 – 8-94
1C5-9-61-05 22/3/04 5:39 PM Page 3

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.)
1C5-9-61-05 22/3/04 5:39 PM Page 12

5-13
cC
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.
1C5-9-61-05 22/3/04 5:39 PM Page 14

8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:8For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
8For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind
that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
INITIAL EVERY
month 1 3 6 6 12
ITEM ROUTINEWhichever
km 320 1200 2400 2400 4800 comes first
(mi) (200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
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.
111 1
• 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
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8
8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.INITIAL EVERY
month 1 3 6 6 12
ITEM ROUTINEWhichever
km 320 1200 2400 2400 4800 comes first
(mi) (200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
Oil strainer*• Clean.
11 1
• 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.
Brakes*• Check operation.
11111
• Adjust if necessary.
V-belt*• Check operation.
11
• Replace if damage or excessive wear.
Wheels*• Check balance/damage/runout.
1111
• Replace if necessary.
Wheel bearings*• Check bearing assembly for looseness/damage.
1111
• Replace if damaged.
• Check operation.
Steering system*• Replace if damaged.
11111
• Check toe-in.
• Adjust if necessary.
Knuckle shafts/• Lubricate every 6 months with lithium-soap-based
111
steering shaft*grease.
Fittings and fasteners*• Check all chassis fittings and fasteners.
11111
• Correct if necessary.
• Check specific gravity.
Battery*• Check breather hose for correct routing.11111
• Correct if necessary.
1C5-9-61-08 9/4/04 9:30 AM Page 8-9