engine YAMAHA GRIZZLY 250 2010 Service Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2010, Model line: GRIZZLY 250, Model: YAMAHA GRIZZLY 250 2010Pages: 140, PDF Size: 4.79 MB
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4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24060Valve 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.
EBU24071Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance and
lubrication chart.EBU29601Brakes Replacement of brake components requires pro-
fessional knowledge. Brake service should be per-
formed by a Yamaha dealer.
WARNING
EWB02571Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.EBU24120Checking the front brake pads and rear
brake shoes The front brake pads and the rear brake shoes
must be checked for wear at the intervals specified
in the periodic maintenance and lubrication chart.
1. Rubber cover
2. Locknut
3. Throttle cable free play adjusting bolt
4. Throttle cable free playU1P065E0.book Page 27 Monday, August 31, 2009 1:10 PM
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8a. Remove the footboard. (See “Engine oil”
on page 8-11 for removal and installation
procedures.)
b. Loosen the locknuts at the brake pedal.
c. Turn the brake pedal position adjusting
bolt at the brake pedal in direction (a) to
raise the brake pedal, and in direction (b)
to lower it.
d. Tighten the locknuts at the brake pedal.
2.Adjusting the brake pedal free playThe brake pedal free play should measure
20.0–30.0 mm (0.79–1.18 in) as shown. If the
free play is incorrect, adjust it as follows.
a. Fully loosen the brake lever free play ad-
justing nut on the brake cable at the rear
wheel hub.
b. Turn the brake pedal free play adjusting
nut on the brake rod at the rear wheel hub
in direction (a) to increase the free play,
and in direction (b) to decrease it.
1. Locknut
2. Brake pedal position adjusting bolt
3. Brake pedal position
1. Brake pedal free play
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8 The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
1. Remove the footboard. (See “Engine oil” on
page 8-11 for removal and installation proce-
dures.)
2. Turn the adjusting nut while holding the brake
light switch in place. To make the brake light
come on earlier, turn the adjusting nut in direc-
tion (a). To make the brake light come on lat-
er, turn the adjusting nut in direction (b).
3. Install the footboard.
EBU24803Adjusting the clutch free play The clutch free play must be adjusted periodically.
Adjust the free play as follows.
1. Remove the footboard. (See “Engine oil” on
page 8-11 for removal and installation proce-
dures.)
2. Loosen the locknut.
3. Slowly turn the clutch adjusting screw in direc-
tion (a) until resistance is felt, and then turn it
1/8 turn in direction (b).
1. Brake light switch
2. Rear brake light switch adjusting nut
1. Locknut
2. Clutch adjusting screw
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TIPTurning the clutch adjusting screw in direction (a)
decreases clutch free play and turning it in direc-
tion (b) increases clutch free play.4. Tighten the locknut to the specified torque.TIPWhen tightening the locknut, hold the clutch ad-
justing screw with a screwdriver so that it does not
turn together with the locknut.5. Install the footboard.EBU24901Checking 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
EWB02581Inspect 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
restrict the operation of controls and lead to
an accident or injury.Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision.EBU28711Checking and lubricating the front and
rear brake levers The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary. Tightening torque:
Locknut:
15 Nm (1.5 m·kgf, 11 ft·lbf)Recommended lubricant:
Engine oil
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EBU25791Troubleshooting chart
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the ATV.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the ATV.
The engine does not start.
Have a Yamaha dealer
check the ATV.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the electrolyte level, recharge the
battery and check the lead connections.
DryWet
Open the throttle halfway and operate
the electric starter.
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EBU25860
CLEANING AND STORAGE
EBU25881Cleaning 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 wheel axles.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
WARNING! Wet brakes may have reduced
stopping ability, increasing the chance of
an accident. Test the brakes after washing.
Apply the brakes several times at slow
speeds to let friction dry out the linings.
[EWB02311]
NOTICE: Excessive water pressure
may cause water seepage and deteriora-tion of wheel bearings, brakes, transmis-
sion seals and electrical devices. Many
expensive repair bills have resulted from
improper high-pressure detergent applica-
tions such as those available in coin-oper-
ated car washers.
[ECB00711]
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. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
7. 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.
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EBU25933Storage Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover. NOTICE: Storing the ATV in a poorly ven-
tilated room or covering it with a tarp while it is
still wet, will allow water and humidity to seep
in and cause rust. To prevent corrosion, avoid
damp cellars, stables (because of the presence
of ammonia) and areas where strong chemi-
cals are stored.
[ECB00721]
Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”
section of this chapter.
2. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float chamber by loosen-
ing the drain bolt; this will prevent fuel deposits
from building up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorat-
ing.5. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.)
e. Remove the spark plug cap from the spark
plug, and then install the spark plug and
the spark plug cap.
6. Lubricate all control cables and the pivoting
points of all levers and pedals.
7. Check and, if necessary, correct the tire air
pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternative- Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1
oz of stabilizer to each gallon of fuel)U1P065E0.book Page 2 Monday, August 31, 2009 1:10 PM
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EBU25960
SPECIFICATIONS
Dimensions:Overall length:
1916 mm (75.4 in)
Overall width:
1038 mm (40.9 in)
Overall height:
1118 mm (44.0 in)
Seat height:
772 mm (30.4 in)
Wheelbase:
1170 mm (46.1 in)
Ground clearance:
150 mm (5.9 in)
Minimum turning radius:
2900 mm (114 in)Weight:With oil and fuel:
216.0 kg (476 lb)Noise and vibration level:Noise level (77/311/EEC):
YFM25BZ 77.5 dB(A)
Vibration on seat (EN1032, ISO5008):
YFM25BZ Will not exceed 0.5 m/s²
Vibration on handlebar (EN1032, ISO5008):
YFM25BZ Will not exceed 2.5 m/s²Engine:Engine type:
Air cooled 4-stroke, SOHCCylinder arrangement:
Forward-inclined single cylinder
Displacement:
229 cm³
Bore × stroke:
71.0 × 58.0 mm (2.80 × 2.28 in)
Compression ratio:
8.70 :1
Starting system:
Electric and recoil starter
Lubrication system:
Wet sump
Engine oil:Recommended brand:
YAMALUBE
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Type:
SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W-
50
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
Engine oil quantity:
Without oil filter element removal:
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter element removal:
1.60 L (1.69 US qt, 1.41 Imp.qt)Final gear oil:Type:
SAE 80 API GL-4 Hypoid gear oil
Quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
Air filter:Air filter element:
Dry elementFuel:Recommended fuel:
YFM250Z Unleaded gasoline only
YFM25BZ Regular unleaded gasoline only
Fuel tank capacity:
12.0 L (3.17 US gal, 2.64 Imp.gal)
Fuel reserve amount:
1.6 L (0.42 US gal, 0.35 Imp.gal)Carburetor:Type × quantity:
BSR33 x 1Spark plug (s):Manufacturer/model:
NGK/DR7EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, centrifugal automaticTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
73/22 (3.318)
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
19/18 × 46/11 (4.414)
0 10 30 50 70 90 110 130 ˚F
–20 –10 0 10 20 30 40 50 ˚CSAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40SAE 20W-50
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INDEX
AAccessories and loading ................................................ 6-8
Air filter element, cleaning ............................................ 8-20BBattery ................................................................... 5-6, 8-38
Brake fluid, changing ................................................... 8-29
Brake fluid level, checking ........................................... 8-29
Brake lever free play, checking the front ...................... 8-30
Brake lever, front ............................................................ 4-4
Brake levers, checking and lubricating ........................ 8-35
Brake light switches ..................................................... 8-33
Brake pads and shoes, checking ................................. 8-27
Brake pedal and rear brake lever ................................... 4-5
Brake pedal, checking and lubricating ......................... 8-36
Brake pedal position, free play and brake lever free
play (rear), adjusting .................................................. 8-30
Brakes .......................................................................... 8-27
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-35
Carburetor, adjusting ................................................... 8-25
Carrier, front ................................................................. 4-13
Carrier, rear .................................................................. 4-13
Chassis fasteners .......................................................... 5-6
Cleaning ......................................................................... 9-1
Clutch free play, adjusting ............................................ 8-34DDrive select lever ........................................................... 4-7Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ........ 8-27
EEngine break-in .............................................................. 6-6
Engine, cold start ........................................................... 6-1
Engine idling speed ..................................................... 8-25
Engine oil ....................................................................... 5-3
Engine oil and oil filter element .................................... 8-11
Engine, starting a warm ................................................. 6-2
Engine stop switch ......................................................... 4-2FFinal gear oil ......................................................... 5-3, 8-17
Fuel ......................................................................... 4-8, 5-3
Fuel cock ....................................................................... 4-9
Fuel tank cap ................................................................. 4-7
Fuse, replacing ............................................................ 8-42HHandlebar switches ....................................................... 4-2
Headlight beam, adjusting ........................................... 8-44
Headlight bulb, replacing ............................................. 8-42
Horn switch .................................................................... 4-3IIdentification numbers .................................................. 11-1
Indicator lights ................................................................ 4-2
Instruments, lights and switches .................................... 5-6LLabel locations ............................................................... 1-1
Light switch .................................................................... 4-3
U1P065E0.book Page 1 Monday, August 31, 2009 1:10 PM