warning YAMAHA GRIZZLY 125 2009 Service Manual

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6. Wash the sponge material gently but thor-
oughly in solvent.
WARNING

EWB01940
Always use parts cleaning solvent to clean the
sponge material. Never use low-flash-point
solvents or gasoline to clean the sponge mate-
rial because the engine could catch fire or ex-
plode.
7. Squeeze the excess solvent out of the spongematerial and let it dry.
NOTICE
ECB00440
Do not twist the sponge material when squeez-
ing it.
8. Check the sponge material and replace it if
damaged.
9. Apply a quality foam air filter oil to the sponge
material.
TIP

The sponge material should be wet but not drip-
ping.
10. Pull the sponge material over the air filter ele-
1. Bolt
2. Washer
3. Sponge material
4. Air filter element frame
3 4
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8. Tighten the locknut at the brake lever.
9. Install the V-belt air filter element cover by in-
stalling the screw.
10. Connect the coupler, and then install the pan-
el by installing the quick fasteners.
11. Install the front carrier by installing the bolts.
WARNING

EWB02080
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.After servicing:

Make sure the brakes operate smoothly and
that the free play is correct.

Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EBU24491
Adjusting the rear 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 rear brake shoes for wear.
The brake lever free play should measure 5.0–8.0
mm (0.20–0.31 in) as shown. If the free play is in-
correct, adjust it as follows.
1. Locknut
2. Brake lever free play adjusting bolt
3. Brake lever free play
3
1
2
(b)
(a)

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Turn the brake lever free play adjusting nut on the
rear wheel hub in direction (a) to increase the free
play, and in direction (b) to decrease it.
If the correct free play cannot be obtained, have a
Yamaha dealer adjust it.
WARNING

EWB02080
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly and
that the free play is correct.

Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
1. Brake lever free play
1

1. Brake lever free play adjusting nut
1
(a)
(b)

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NOTICE

ECB00560
The drive chain must be lubricated after wash-
ing the ATV or riding in the rain.
1. Clean the drive chain with kerosene and a
small soft brush.
NOTICE

ECB00570
To prevent damaging the O-rings, do not clean
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents.
2. Wipe the drive chain dry.3. Thoroughly lubricate the drive chain with a
special O-ring chain lubricant.NOTICE
ECB00580
Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings.
EBU24900
Checking and lubricating the cables
The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.WARNING

EWB02130
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to an
1. O-ring
1

Recommended lubricant:
Engine oil

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TIP

The electrolyte should be between the minimum
and maximum level marks.
3. If the electrolyte is at or below the minimum
level mark, add distilled water to raise it to the
maximum level mark.
NOTICE
ECB00590
Use only distilled water, as tap water contains
minerals that are harmful to the battery.
WARNING

EWB02160
Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
1. Battery
2. Battery breather hose
3. Guide
1
2
3

1. Maximum level mark
2. Minimum level mark
1
2

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If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.
NOTICE

ECB00640
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.
2. Remove the blown fuse, and then install a
new fuse of the specified amperage.
WARNING

EWB02171
Always use a fuse of the specified rating, and
never use a substitute object in place of the
proper fuse. An improper fuse or a substitute
object can cause damage to the electrical sys-
tem, which could lead to a fire.
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.
EBU25480
Replacing a headlight bulb
If a headlight bulb burns out, replace it as follows.
1. Remove the cover at the rear of the headlight
by pulling it off.
2. Remove the headlight bulb holder cover by
pulling it off. Specified fuse:
15.0 A
1. Cover at the rear of the headlight
1

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3. Remove the headlight bulb holder by pushing
it in and turning it counterclockwise.
4. Remove the defective bulb by pulling it out.
WARNING

EWB02220
A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool before touching or removing it. You can
be burned or a fire could start if the bulb touch-
es something flammable.
5. Insert a new headlight bulb into the bulb hold-er by pushing it in.
NOTICE
ECB00650
Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of the
bulb, and the bulb life will be adversely affect-
ed. Thoroughly clean off any dirt and finger-
prints on the headlight bulb using a cloth
moistened with alcohol or thinner.
6. Install the bulb holder by pushing it in and turn-
ing it clockwise.
1. Headlight bulb holder cover
2. Headlight bulb holder
12

1. Headlight bulb1

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EBU25720
Troubleshooting
Although Yamaha ATVs receive a thorough in-
spection before shipment from the factory, trouble
may occur during operation. Any problem in the fu-
el, compression, or ignition systems, for example,
can cause poor starting and loss of power.
The following troubleshooting chart represents a
quick and easy procedure for checking these vital
systems yourself. However, should your ATV re-
quire any repair, take it to a Yamaha dealer, whose
skilled technicians have the necessary tools, expe-
rience, and know-how to service the ATV properly.
Use only genuine Yamaha replacement parts. Im-
itation parts may look like Yamaha parts, but they
are often inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING

EWB02280
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe inju-
ry or property damage. Make sure there are no
open flames or sparks in the area, including pi-
lot lights from water heaters or furnaces.
Tightening torques:
Front wheel nut:
55 Nm (5.5 m·kgf, 39.8 ft·lbf)
Rear wheel nut:
55 Nm (5.5 m·kgf, 39.8 ft·lbf)

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EBU25860
CLEANING AND STORAGE
EBU25900
Cleaning
Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.
1. Before cleaning the ATV:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps
are properly installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply de-
greaser to the chain, sprockets or wheel ax-
les.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
NOTICE

ECB00710
Excessive water pressure may cause water
seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical de-
vices. Many expensive repair bills have result-ed from improper high-pressure detergent
applications such as those available in coin-
operated car washers.
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bot-
tle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean wa-
ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Dry the chain and lubricate it to prevent it from
rusting.
7. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
WARNING
EWB02310
Wet brakes may have reduced stopping ability,