2010 YAMAHA GRIZZLY 125 transmission

EBU17420
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 1-1
SAFETY INFORMATION .............................. 2-1
DESCRIPTION .............................................. 3-1
Left view ..................................................... 3-1
Right view................................................... 3-1
Controls and instruments ........................... 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ............................................... 4-1
Indicator lights ........................................... 4-1
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Speed limiter ............................................. 4-3
Front brake lever ....................................... 4-4
Rear brake lever ........................................ 4-4
Parking brake ............................................ 4-5
Drive select lever ....................................... 4-6
Fuel tank cap ............................................. 4-6
Fuel ........................................................... 4-6
Fuel cock ................................................... 4-8
Starter (choke) .......................................... 4-9Seat ......................................................... 4-10
Front carrier ............................................. 4-11
Rear carrier .............................................. 4-11
PRE-OPERATION CHECKS ..........................5-1
Fuel ............................................................ 5-3
Engine oil ................................................... 5-3
Transmission oil ......................................... 5-3
Front and rear brakes ................................ 5-3
Throttle lever .............................................. 5-3
Drive chain ................................................. 5-3
Tires ........................................................... 5-3
Chassis fasteners ...................................... 5-5
Instruments, lights and switches ................ 5-6
Battery ....................................................... 5-6
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2
Operating the drive select lever and
driving in reverse .....................................6-3
Engine break-in .......................................... 6-4
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-5
Accessories and loading ............................ 6-6

RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGMENT ............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............ 7-9
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-13
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER .................................................. 7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND
ADJUSTMENT ............................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance chart for the
emission control system .......................... 8-3
General maintenance and lubrication
chart ........................................................ 8-5
Checking the spark plug ............................ 8-8
Engine oil .................................................. 8-9
Transmission oil ...................................... 8-12
Cleaning the engine and V-belt case
air filter elements ................................... 8-15
Cleaning the spark arrester ..................... 8-21V-belt case drain plug .............................. 8-23
Adjusting the carburetor ........................... 8-23
Adjusting the engine idling speed ............ 8-23
Adjusting the throttle cable free play ........ 8-24
Valve clearance ....................................... 8-25
Brakes ...................................................... 8-26
Checking the front and rear brake
shoes .....................................................8-26
Adjusting the front brake lever free
play ........................................................8-27
Adjusting the rear brake lever free
play ........................................................8-31
Drive chain slack ...................................... 8-32
Lubricating the drive chain ....................... 8-35
Checking and lubricating the cables ........ 8-36
Checking and lubricating the front
and rear brake levers .............................8-36
Checking the wheel hub bearings ............ 8-37
Lubricating the upper and lower arm
pivots .....................................................8-37
Lubricating the front knuckle pivots ......... 8-38
Lubricating the steering shaft ................... 8-38
Battery ..................................................... 8-39
Replacing the fuse ................................... 8-42
Replacing a headlight bulb ...................... 8-43
Adjusting a headlight beam ..................... 8-45
Replacing the tail/brake light bulb ............ 8-45
Removing a wheel ................................... 8-46
Installing a wheel ..................................... 8-46

5-1
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EBU19201
PRE-OPERATION CHECKS
EBU19224
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWB00481
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-6, 5-3
Engine oil

Check oil level in engine, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-3, 8-9
Transmission oil

Check oil level in transmission case, and add recommended oil to
specified level if necessary.

Check ATV for oil leakage. Correct if necessary.5-3, 8-12
Front brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary.5-3, 8-26, 8-27
Rear brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary.5-3, 8-26, 8-31

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Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-6.)
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Engine oil
Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-9.)
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Transmission oil
Make sure that the transmission oil is at the speci-
fied level. Add oil as necessary. (See page 8-12.)
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Front and rear brakes
Brake levers

Check for correct free play in the brake levers. If
the free play is incorrect, adjust it. (See pages
8-27 and 8-31.)

Check operation of the levers. They should
move smoothly and there should be a firm feel-
ing when the brake is applied. If not, have the
ATV checked by a Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brakes for wear. (See page 8-26.)
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Throttle lever
Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary.
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Drive chain
Check the condition of the drive chain and check
the drive chain slack. Lubricate and adjust the
drive chain as necessary. (See page 8-32.)
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Tires
Check tire pressure regularly to make sure it is at
the recommended specifications. Also check for
wear and damage.
Tire pressure
Use the low-pressure tire gauge to check and ad-
just tire pressures when the tires are cold. Tire

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Operating the drive select lever and
driving in reverse
NOTICE

ECB00170
Before shifting, stop the ATV, otherwise the
transmission may be damaged.
Shifting: Forward
1. Bring the ATV to a complete stop.
2. Shift from neutral to forward and vice versa by
moving the drive select lever along the shift
guide.
TIP

Make sure that the drive select lever is completely
shifted into position.
3. Open the throttle lever gradually.
Shifting: ReverseWARNING

EWB00720
Improper operation in reverse could make you
hit an obstacle or even a person behind you,
resulting in serious injury. When you shift into
reverse, make sure there are no people or ob-
stacles behind you. When it is safe to proceed,
1. Neutral “N”
2. Forward “F”
3. Reverse “R”
4. Drive select lever
1
2
3
4

8-6
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8 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if neces-
sary.

Clean and lubricate.
√√√√√
9
*
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.
√√
18
*
Moving parts and
cables


Lubricate.
√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320

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8. Refill with the specified amount of the recom-
mended engine oil, and then install and tight-
en the engine oil filler cap.
TIP

Be sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down.
NOTICE

ECB00330

Do not use oils with a diesel specification of
“CD” or oils of a higher quality than speci-
fied. In addition, do not use oils labeled “EN-
ERGY CONSERVING II” or higher.

Make sure that no foreign material enters the
crankcase.
9. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
10. Turn the engine off, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
EBU27025
Transmission oil
The transmission oil level should be checked be-
fore each ride. In addition, the transmission oil
must be changed at the intervals specified in the
periodic maintenance and lubrication chart.
To check the transmission oil level
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. Wait a few minutes until the oil settles, and
then loosen the transmission oil check screw
located at the right side of the crankcase until
oil flows out. Tightening torque:
Engine oil drain bolt:
32 Nm (3.2 m·kgf, 23.1 ft·lbf)
Recommended oil:
See page 10-1.
Oil quantity:
1.25 L (1.32 US qt, 1.10 Imp.qt)

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4. If no oil flows out, remove the oil filler bolt.5. Pour the recommended type of oil in the trans-
mission oil filler hole until it flows out of the
check screw hole.
6. Install the transmission oil check screw and
transmission oil filler bolt, and then tighten
them to the specified torques.
1. Transmission oil check screw
2. Transmission oil level check hole
3. Correct oil level
1 32

1. Transmission oil filler bolt
Tightening torque:
Transmission oil check screw:
16 Nm (1.6 m·kgf, 11.6 ft·lbf)
Transmission oil filler bolt:
23 Nm (2.3 m·kgf, 16.6 ft·lbf)
1