2009 YAMAHA GRIZZLY 125 engine

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EBU28781
PERIODIC MAINTENANCE AND MINOR REPAIR
EBU21670
Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.
WARNING

EWB01840
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or start fires. Turn off the en-
gine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform the service if you are not familiar with
maintenance work.
EBU27110
Owner’s manual and tool kit
Be sure to put this owner’s manual in the plastic
bag and to always carry it as well as the owner’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.
1. Owner’s manual
2. Low-pressure tire gauge
3. Owner’s tool kit
1
2 3

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EBU21742
Periodic maintenance chart for the emission control system
TIP


For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 3201
*
Fuel line


Check fuel hoses for cracks or other damage, and
replace if necessary.
√√√
2 Spark plug

Check condition and clean, regap, or replace if
necessary.
√√√√√
3
*
Valves


Check valve clearance and adjust if necessary.
√ √√√
4
*
Carburetor


Check starter (choke) operation and correct if nec-
essary.

Check engine idling speed and adjust if neces-
sary.
√√√√
5
*
Crankcase breather
system


Check breather hose for cracks or other damage,
and replace if necessary.
√√√

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EBU21864
General maintenance and lubrication chart
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 3201Engine and V-belt
case air filter ele-
ment


Clean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
2
*
Front brake

Check operation and correct if necessary.

Check brake lever free play and adjust if neces-
sary.
√√√√√

Replace brake shoes. Whenever worn to the limit
3
*
Rear brake

Check operation and correct if necessary.

Check brake lever free play and adjust if neces-
sary.
√√√√√

Replace brake shoes. Whenever worn to the limit
4
*
Wheels

Check runout and for damage, and replace if nec-
essary.
√ √√√
5
*
Tires


Check tread depth and for damage, and replace if
necessary.

Check air pressure and balance, and correct if
necessary.
√ √√√
6
*
Wheel hub bearings


Check for looseness or damage, and replace if
necessary.
√ √√√
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*
Upper and lower
arm pivots


Lubricate with lithium-soap-based grease.
√√√

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8 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if necess-
sary.

Clean and lubricate.
√√√√√
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*
V-belt


Check for wear, cracks or other damage, and
replace if necessary.
√√
10
*
Chassis fasteners


Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
11
*
Shock absorber
assemblies


Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
12
*
Front knuckle piv-
ots


Lubricate with lithium-soap-based grease.
√√√
13
*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
14
*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
15 Engine oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
16 Engine oil strainer

Clean.
√√√
17 Transmission oil


Change.

Check ATV for oil leakage, and correct if neces-
sary.
√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320

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EBU23211
Checking the spark plug
The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with thespark plug wrench included in the owner’s tool
kit.
To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).TIP
If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-
stead, have a Yamaha dealer check the ATV.
1. Spark plug cap
1

1. Spark plug wrench
1

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2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
To install the spark plug
1. Measure the spark plug gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.
TIP
If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
4. Install the spark plug cap.
EBU23265
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 maintenance
and lubrication chart. Specified spark plug:
NGK/CR7HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1. Spark plug gap
Tightening torque:
Spark plug:
12.5 Nm (1.3 m·kgf, 9.0 ft·lbf)

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To check the engine oil level
1. Place the ATV on a level surface.
2. Check the engine oil level on a cold engine.
TIP

If the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil set-
tles for an accurate reading.
3. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
4. Insert the dipstick into the filler hole (withoutscrewing it in), and then remove it again to
check the oil level.TIP
The engine oil should be between the minimum
and maximum level marks.
5. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.
6. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
1. Engine oil tank filler cap
2. Dipstick
2
1

1. Maximum level mark
2. Minimum level mark
1
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To change the engine oil
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place an oil pan under the engine to collect
the used oil.
4. Remove the engine oil filler cap, and then re-
move the engine oil drain bolt to drain the oil
from the crankcase.
NOTICE

ECB00310
When removing the engine oil drain bolt, the
compression spring, oil strainer and O-ring will
fall out. Take care not to lose these parts.
5. Clean the oil strainer with solvent.
6. Check the O-ring for damage and replace it if
necessary.
7. Install the O-ring, oil strainer, compression
spring and drain bolt. Tighten the engine oil
drain bolt to the specified torque.NOTICE
ECB00320
Before installing the engine oil drain bolt, be
sure to install the O-ring, compression spring
and oil strainer.
8. Refill with the specified amount of the recom-
mended engine oil, and then install and tight-
en the engine oil filler cap.
1. Engine oil drain bolt
2. O-ring
3. Spring
4. Oil strainer
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Tightening torque:
Engine oil drain bolt:
32 Nm (3.2 m·kgf, 23.1 ft·lbf)