maintenance YAMAHA GRIZZLY 125 2009 User Guide

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EBU23060
TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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*
Throttle lever hous-
ing and cable

Check operation and correct if necessary.

Check throttle cable free play and adjust if neces-
sary.

Lubricate throttle lever housing and cable.
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Front and rear brake
switches


Check operation and correct if necessary.
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Lights and switches


Check operation and correct if necessary.

Adjust headlight beams.
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Battery

Check electrolyte level and specific gravity, and
correct if necessary.

Make sure that the breather hose is properly
routed.
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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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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
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1. Spark plug wrench
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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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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 remove the screw located at the right
side of the crankcase.
4. Check the transmission oil level.
TIP
The transmission oil should be at the brim of the
hole.
5. If the transmission oil level is below the brim of
the hole, remove the oil filler bolt, add suffi-
cient oil of the recommended type to raise it to
the correct level, and then install and tighten
the screw and the oil filler bolt.
1. Screw
2. Transmission oil level check window
3. Correct oil level
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1. Transmission oil filler bolt
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minutes while checking the transmission for
oil leakage. If oil is leaking, immediately turn
off the engine and check for the cause.
8. Turn the engine off, and then check the oil lev-
el and correct it if necessary.
EBU23841
Cleaning the engine and V-belt case air
filter elements
Both air filter elements should be cleaned at the
specified intervals in the periodic maintenance
chart.
Engine air filter element
TIP

There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case.1. Remove the seat. (See page 4-9.)
2. Remove the breather hose, and then loosen
the clamp screw.
1. Check hose
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ment frame.
11. Install the washer and bolt.
NOTICE

ECB00450
Be sure to install the washer with the bent edge
facing upward as shown.
12. Install the air filter element into the air filter
case.
13. Install the air filter case cover by installing the
screws.
14. Install the breather hose and then tighten the
clamp screw.15. Install the seat.TIP
The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfiltered
air entering the engine.NOTICE

ECB00460

Make sure that the air filter element is prop-
erly seated in the air filter case.

Never operate the engine with the air filter el-
ement removed. This will allow unfiltered air
to enter the engine, causing rapid engine
wear and possible engine damage. Addition-
ally, operation without the air filter element
will affect carburetor jetting with subsequent
poor performance and possible engine over-
heating.
1. Washer
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ter the V-belt case, remove this plug to drain the
water from the case.
TIP

If water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV as
the water may affect other engine parts.
EBU23940
Adjusting the carburetor
The carburetor should be checked and, if neces-
sary, adjusted at the intervals specified in the peri-
odic maintenance and lubrication chart. The
carburetor is an important part of the engine andrequires very sophisticated adjustment. Therefore,
most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary profes-
sional knowledge and experience. The adjustment
described in the following section, however, may
be performed by the owner as part of routine main-
tenance.NOTICE
ECB00480
The carburetor has been set and extensively
tested at the Yamaha factory. Changing these
settings without sufficient technical knowl-
edge may result in poor performance of or
damage to the engine.
EBU24000
Adjusting the engine idling speed
The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
TIP

A diagnostic tachometer is needed to make this
adjustment.
1. Start the engine and warm it up.
1. V-belt case drain plug
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TIP

The engine is warm when it quickly responds to the
throttle.
2. Attach the tachometer to the spark plug lead.
3. Check the engine idling speed and, if neces-
sary, adjust it to specification by turning the
throttle stop screw at the carburetor. To in-
crease the engine idling speed, turn the throt-
tle stop screw in direction (a), and to decrease
it, turn the screw in direction (b).TIP
If the specified idling speed cannot be obtained as
described above, have a Yamaha dealer make the
adjustment.
EBU24044
Adjusting the throttle cable free play
The throttle cable free play should be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
The throttle cable free play should measure 1.0–
3.0 mm (0.04–0.12 in) at the throttle lever. Period-
ically check the throttle cable free play and, if nec-
essary, adjust it as follows.TIP

The engine idling speed must be checked, and ad-
justed if necessary, before adjusting the throttle ca-
ble free play.
1. Loosen the locknut.
2. To increase the throttle cable free play, turn
the throttle cable free play adjusting bolt in di-
rection (a). To decrease the throttle cable free
play, turn the adjusting bolt in direction (b).
1. Throttle stop screw
Engine idling speed:
1650–1750 r/min
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3. Tighten the locknut.
EBU24060
Valve clearance
The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24090
Checking the front and rear brake
shoes
The front and rear brake shoes must be checked
for wear at the intervals specified in the periodic
maintenance and lubrication chart. Each brake is
provided with a wear indicator, which allows you to
check the brake shoe wear without having to dis-
assemble the brake. To check the brake shoe
wear, check the position of the wear indicator while
applying the brake. If a brake shoe has worn to the
point that the wear indicator reaches the wear limit
line or mark, have a Yamaha dealer replace the
brake shoes as a set.
1. Locknut
2. Throttle cable free play adjusting bolt
3. Throttle cable free play
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(a) (b)

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Front brake Rear brake

EBU24370
Adjusting the front brake lever free
play
The brake lever free play must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.TIP
Before adjusting the brake lever free play, check
the front brake shoes for wear.
The brake lever free play should measure 5.0–8.0
1. Wear limit line
2. Wear indicator
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1. Wear limit line
2. Wear indicator
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