Yamaha GRIZZLY 125 Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM125GT

wThis ATV should not be ridden by anyone under 16 years of age.

LIT-11626-18-19

1C5-28199-11

EBU13290

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM125G. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

8READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

8PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

8NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.

8THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

EBU00801

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

Q

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

wFailure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EBU15000

IMPORTANT NOTICE

This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.

This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this ATV.

YFM125GT

EBU13330

OWNER'S MANUAL

© 2004 by Yamaha Motor Corporation, U.S.A.

AFFIX DEALER

1st edition, April 2004

LABEL HERE

All rights reserved.

Any reprinting or unauthorized use without the written permission

of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan.

P/N LIT-11626-18-19

EBU00014

w

Indicates a potential hazard that could result in serious injury or death.

CONTENTS

1

2

3

LOCATION OF THE WARNING AND		4	CONTROL FUNCTIONS	..........................4-1
.......................SPECIFICATION LABELS	1-1		...........................................Main switch	4-1
			Indicator lights ......................................	4-2
			Handlebar switches ..............................	4-2
			Throttle lever ........................................	4-4
SAFETY INFORMATION .........................	2-1		Speed limiter ........................................	4-5
			Front brake lever ..................................	4-6
			Rear brake lever...................................	4-6
			Parking brake .......................................	4-7
DESCRIPTION AND MACHINE			Drive select lever ..................................	4-8
IDENTIFICATION.....................................	3-1		Fuel tank cap........................................	4-8
Identification number records ...............	3-2		Fuel cock ..............................................	4-9
Key identification number .....................	3-2		Starter (choke)....................................	4-10
Vehicle identification number ...............	3-3		Seat ....................................................	4-10
Model label ...........................................	3-3		Front carrier ........................................	4-11
			Rear carrier ........................................	4-11

5

6

PRE-OPERATION CHECKS ...................	5-1		Parking .................................................	6-7
Front and rear brakes ...........................	5-2		Parking on a slope................................	6-8
Fuel ......................................................	5-3		Accessories and loading ......................	6-9
Engine and transmission oil .................	5-5
Chain ....................................................	5-6
Throttle lever	5-6		Riding Your ATV	7-1
		7
Fittings and fasteners ...........................	5-6		Getting to know your ATV .....................	7-3
Lights....................................................	5-6		Ride with care and good
Switches ...............................................	5-6		judgement...........................................	7-4
Battery ..................................................	5-6		Be careful where you ride...................	7-16
Tires .....................................................	5-7		Turning your ATV ...............................	7-22
How to measure tire pressure ..............	5-8		Climbing uphill ....................................	7-24
Tire wear limit .......................................	5-9		Riding downhill ...................................	7-30
			Crossing a slope.................................	7-32
			Crossing through shallow water .........	7-34
OPERATION ............................................	6-1		Riding over rough terrain....................	7-36
Starting a cold engine...........................	6-1		Sliding and skidding ...........................	7-38
Starting a warm engine ........................	6-3		What to do if .......................................	7-40
Warming up ..........................................	6-3		What to do ..........................................	7-40
Drive select lever operation and
reverse driving ....................................	6-4
Engine break-in ....................................	6-6

8	PERIODIC MAINTENANCE AND	8-1
	ADJUSTMENT .........................................
	.................Owner’s manual and tool kit	8-1
	Periodic maintenance/Lubrication ........	8-3
	Engine oil..............................................	8-5
	Final transmission oil ............................	8-7
	Spark plug inspection ...........................	8-9
	Engine air filter element and V-belt
	case air filter element cleaning .........	8-11
	Spark arrester cleaning ......................	8-16
	Idle speed adjustment ........................	8-17
	Valve clearance adjustment ...............	8-18
	Throttle lever adjustment....................	8-19
	Front and rear brake shoe
	inspection .........................................	8-20
	Front brake lever free play
	adjustment........................................	8-21
	Rear brake adjustment .......................	8-25
	Drive chain slack check......................	8-26
	Drive chain slack adjustment..............	8-27
	Lubricating the drive chain .................	8-29

	Draining the V-belt compartment	........8-30
	Cable inspection and lubrication ........	8-30
	Brake lever lubrication........................	8-31
	Knuckle shaft, lower arms and
	steering shaft lubrication ..................	8-31
	Wheel removal ...................................	8-32
	Wheel installation ...............................	8-32
	Battery ................................................	8-33
	Replenishing the battery fluid .............	8-35
	Fuse replacement...............................	8-36
	Replacing the headlight bulb ..............	8-37
	Tail/brake light bulb replacement .......	8-39
	Headlight beam adjustment................	8-40
	Troubleshooting..................................	8-41
	Troubleshooting chart.........................	8-42
	CLEANING AND STORAGE	9-1
9
	A. CLEANING .......................................	9-1
	B. STORAGE .......................................	9-3
	SPECIFICATIONS	10-1
10

11	............................NOISE REGULATION	11-1
12	....................MAINTENANCE RECORD	12-1
13	...................ATV LIMITED WARRANTY	13-1
	YAMAHA EXTENDED SERVICE
14
	(Y.E.S.)...................................................	14-1

EBU00464

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

6 8

1

5

2

4

3

7 8

1-1

Read and understand all of the labels on your	2	1
machine. They contain important information for
safe and proper operation of your ATV.
Never remove any labels from your ATV. If a
label becomes difficult to read or comes off, a
replacement label is available from your
Yamaha dealer.
1

1C5-21696-00

3

5FE-21697-01

qWARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

5FE-2151H-01

1-2

4

5

DRIVE SELECT LEVER

8 Read owner’s manual carefully before operating.

8 When shifting the drive select lever, always be sure to stop the ATV and apply the rear brake.

5YT-2151E-30

6

5kg 11lbs

3LD-24877-A0

7

10kg 22lbs

1C5-24877-A0

8

NEVER sit here.

3MX-24875-A0

5FE-21568-01

1-3

EBU13360

qSAFETY INFORMATION

2

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

An ATV handles differently from other vehicles including motorcycles 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 training or instruction. Take a Training Course.

Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you.

8Always follow the age recommendation:

- A child under 16 years old should never operate an ATV with engine size greater than 90cc.

8Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

8Never carry a passenger on an ATV.

2-1

8Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

8Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

8Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

8Never consume alcohol or drugs before or while operating this ATV.

8Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

8Never attempt wheelies, jumps, or other stunts.

8Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

8Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

8Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

2-2

8Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

8Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

8Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

8Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed.

8Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

8Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

2-3

8Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

8Always check for obstacles before operating in a new area.

Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

8Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

8Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

8Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

8Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

8Never modify an ATV through improper installation or use of accessories.

2-4

8Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

2-5

qWARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

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.

When transporting the ATV 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.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow 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.

2-6

qWARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD

Always operate your ATV in an area with adequate ventilation.

2-7

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION

1

2

3

4

5

6

7

8 9 0

					q
	r t		1.	Seat	11.	Footboard
w e		y	2.	Drive select lever	12.	Rear brake lever
			3.	Front cover	13.	Parking brake
			4.	Headlight	14.	Reverse indicator light
			5.	Front carrier	15.	Neutral indicator light
			6.	Starter (choke)	16.	Front brake lever
			7.	Fuel cock	17.	Throttle lever
			8.	Tail/brake light	18.	Main switch
			9.	Rear carrier	19.	Fuel tank cap
			10.	Spark arrester	20.	Handlebar switches
			NOTE:
			The machine you have purchased may differ
p	o	i u	slightly from those shown in the figures of this

3-1 manual.

EBU00600

Identification number records

Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1.KEY IDENTIFICATION NUMBER:

2.VEHICLE IDENTIFICATION NUMBER:

3.MODEL LABEL INFORMATION:

1

6

EBU00035
Key identification number
The key identification number is stamped on the
key as shown in the following illustration. This
number can be used for ordering a new key.	3

q

1. Key identification number

3-2

EBU00036

Vehicle identification number

The vehicle identification number is stamped into the frame.

q

1. Vehicle identification number

NOTE:

The vehicle identification number is used to identify your machine.

EBU00787

Model label

The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

1

1. Model label

3-3

EBU00039
CONTROL FUNCTIONS	OFF	ON
w
Indicates a potential hazard that could result		4
in serious injury or death.

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.

4-1

EBU00043

Indicator lights

	1 2
1.	Reverse indicator light “R”
2.	Neutral indicator light “N”

EBU12500

Reverse indicator light “R”

This indicator light comes on when the drive select lever is in the “R” position.

EBU09720

Neutral indicator light “N”

This indicator light comes on when the drive select lever is in the “N” position.

EBU00053

Handlebar switches

w

q

e

1.Engine stop switch “ENG. STOP”

2.Light switch “LIGHTS”

3.Start switch “START”

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”.

4-2

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 6-1 for details).

NOTE:

If the starter switch is pushed with the main switch “ON” and the engine stop switch “OFF”, the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at “RUN”.

EBU14770

Light switch “LIGHTS”

Set the switch to the “LO” position to turn on the low beam and the taillight.

Set the switch to the “HI” position to turn on the high beam and the taillight.

Set the switch to the “OFF” position to turn off all of the lights.

cC

Do not use the headlights with the engine turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it.

4-3

EBU00062

Throttle lever

Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

q

1. Throttle lever

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

qWARNING

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the problem yourself.

4-4

EBU11590

Speed limiter

The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV.

w

q	a

1. Adjusting screw 2. Locknut a. No more than 12 mm (0.47 in)

qWARNING

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). See page 8-19.

4-5

EBU00070

Front brake lever

The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

q

1. Front brake lever

EBU00072

Rear brake lever

The rear brake lever is located on the left handlebar. Pull it toward the handlebar to apply the rear brake.

q

1. Rear brake lever

4-6

EBU00074

Parking brake

Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

q

1. Lock plate

qWARNING

POTENTIAL HAZARD

Improper use of the parking brake.

WHAT CAN HAPPEN

The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision.

The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.

HOW TO AVOID THE HAZARD

Always set the parking brake before starting the engine.

Always be sure you have released the parking brake before you begin to ride.

4-7

EBU11060

Drive select lever

The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 6-4 for the drive select lever operation.)

	1
3		2
		a
a. Drive select lever	1.	Neutral
2. Forward	3.	Reverse

EBU00092

Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

1

1. Fuel tank cap

4-8