Yamaha GRIZZLY 125 User Manual
OWNER’S MANUAL
READ THIS MANUAL CAREFULLY!
It contains important safety information.
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YFM125GT
LIT-11626-18-19 1C5-28199-11
This ATV should not be ridden by anyone under 16 years of age.
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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 regard-
ing the operation or maintenance of your ATV, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-
PLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
8 NEVER 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.
8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER
16 YEARS OF AGE.
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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!
w Failure 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.
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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.
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AFFIX DEALER
LABEL HERE
YFM125GT
OWNER'S MANUAL
© 2004 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2004
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
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Indicates a potential hazard that could result
in serious injury or death.
CONTENTS
LOCATION OF THE WARNING AND
1
SPECIFICATION LABELS.......................1-1
SAFETY INFORMATION.........................2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION.....................................3-1
Identification number records ...............3-2
Key identification number .....................3-2
Vehicle identification number ...............3-3
Model label ...........................................3-3
CONTROL FUNCTIONS..........................4-1
4
Main switch ...........................................4-1
Indicator lights ......................................4-2
Handlebar switches ..............................4-2
Throttle lever ........................................4-4
Speed limiter ........................................4-5
Front brake lever ..................................4-6
Rear brake lever...................................4-6
Parking brake .......................................4-7
Drive select lever..................................4-8
Fuel tank cap........................................4-8
Fuel cock ..............................................4-9
Starter (choke)....................................4-10
Seat ....................................................4-10
Front carrier........................................4-11
Rear carrier ........................................4-11
PRE-OPERATION CHECKS ...................5-1
5
Front and rear brakes ...........................5-2
Fuel ......................................................5-3
Engine and transmission oil .................5-5
Chain ....................................................5-6
Throttle lever ........................................5-6
Fittings and fasteners ...........................5-6
Lights....................................................5-6
Switches ...............................................5-6
Battery ..................................................5-6
Tires .....................................................5-7
How to measure tire pressure ..............5-8
Tire wear limit .......................................5-9
OPERATION............................................6-1
6
Starting a cold engine...........................6-1
Starting a warm engine ........................6-3
Warming up ..........................................6-3
Drive select lever operation and
reverse driving....................................6-4
Engine break-in ....................................6-6
Parking .................................................6-7
Parking on a slope................................6-8
Accessories and loading ......................6-9
Riding Your ATV.......................................7-1
7
Getting to know your ATV.....................7-3
Ride with care and good
judgement...........................................7-4
Be careful where you ride...................7-16
Turning your ATV ...............................7-22
Climbing uphill ....................................7-24
Riding downhill ...................................7-30
Crossing a slope.................................7-32
Crossing through shallow water .........7-34
Riding over rough terrain....................7-36
Sliding and skidding ...........................7-38
What to do if .......................................7-40
What to do ..........................................7-40
PERIODIC MAINTENANCE AND
8
ADJUSTMENT.........................................8-1
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
NOISE REGULATION............................11-1
11
12
MAINTENANCE RECORD ....................12-1
13
ATV LIMITED WARRANTY ...................13-1
YAMAHA EXTENDED SERVICE
14
(Y.E.S.)...................................................14-1
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5
4
6
8
7
8
2
3
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
Read and understand all of the labels on your
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
5FE-21697-01
1-2
2
3
1C5-21696-00
q
WARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
5FE-2151H-01
1
45
5kg 11lbs
3LD-24877-A0
10kg 22lbs
1C5-24877-A0
sit here.NEVER
3MX-24875-A0
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
7
8
5FE-21568-01
1-3
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q SAFETY INFORMATION
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:
8 Read this manual and all labels carefully and follow the operating procedures described.
8 Never 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.
8 Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow con-
tinued use of an ATV by a child if he or she does not have the abilities to operate it safely.
8 Never carry a passenger on an ATV.
2-1
2
8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots
and streets.
8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8 Never 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.
8 Never consume alcohol or drugs before or while operating this ATV.
8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is prop-
er for the terrain, visibility and operating conditions, and your experience.
8 Never attempt wheelies, jumps, or other stunts.
8 Always 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.
8 Always keep both hands on the handlebars and both feet on the footboards of the ATV during oper-
ation.
8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
2-2
8 Never 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.
8 Always 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.
8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
8 Always 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.
8 Always 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.
8 Always 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
8 Always 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.
8 Always 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.
8 Always 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.
8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu-
al. 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.
8 Always 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.
8 Always use the size and type tires specified in this manual.
Always maintain proper tire pressure as described in this manual.
8 Never modify an ATV through improper installation or use of accessories.
2-4
8 Never 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
q
WARNING
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
q
WARNING
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.
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DESCRIPTION AND MACHINE IDENTIFICATION
1. Seat 11. Footboard
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
slightly from those shown in the figures of this
manual.
3-1
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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
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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.
1. Key identification number
3
3-2
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Vehicle identification number
The vehicle identification number is stamped
into the frame.
1. Vehicle identification number
NOTE:
The vehicle identification number is used to
identify your machine.
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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
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CONTROL FUNCTIONS
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Indicates a potential hazard that could result
in serious injury or death.
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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
4
4-1
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q
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Indicator lights
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Handlebar switches
12
1. Reverse indicator light “R”
2. Neutral indicator light “N”
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Reverse indicator light “R”
This indicator light comes on when the drive
select lever is in the “R” position.
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Neutral indicator light “N”
This indicator light comes on when the drive
select lever is in the “N” position.
1. Engine stop switch “ENG. STOP”
2. Light switch “LIGHTS”
3. Start switch “START”
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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
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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).
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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.
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”.
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
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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.
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.
q
WARNING
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
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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.
1. Adjusting screw 2. Locknut
a. No more than 12 mm (0.47 in)
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WARNING
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
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Front brake lever
The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the
front brake.
1. Front brake lever 1. Rear brake lever
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Rear brake lever
The rear brake lever is located on the left handlebar. Pull it toward the handlebar to apply the
rear brake.
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4-6
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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.
1. Lock plate
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WARNING
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.
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2
3
a
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.)
a. Drive select lever 1. Neutral
2. Forward 3. Reverse
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Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.
1
1. Fuel tank cap
4-8
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