yamaha grizzly 125 Service Repair Manual 2004

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This manual covers the 2004 Grizzly 125, an air-cooled, SOHC, 4-stroke utility ATV. With a 124 cc engine displacement and a focus on reliable off-road performance, the Grizzly 125 is...

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Typ: Atv

Anbieter:

Art.-Nr: 128799

Stichworte: 2004 ATV Grizzly 125 Grizzly Models Powersports Yamaha

Produktvarianten

Beschreibung

This manual covers the 2004 Grizzly 125, an air-cooled, SOHC, 4-stroke utility ATV. With a 124 cc engine displacement and a focus on reliable off-road performance, the Grizzly 125 is designed for enthusiasts and those needing a capable utility vehicle. The extensive legacy in ATV manufacturing ensures a product built with engineering quality and durability in mind, making it a solid choice for various recreational and practical applications. Its robust build and straightforward design contribute to its reputation for reliability. This comprehensive factory service repair manual provides detailed information for maintaining and repairing the 2004 Grizzly 125. It covers all essential systems, including engine overhaul, fuel system maintenance, transmission and drivetrain service, cooling, electrical, brake, and suspension systems. The manual includes routine maintenance procedures, troubleshooting guides for common issues, and in-depth instructions for component rebuilds, such as the carburetor and engine. With over 250 pages of factory-level documentation, this English-language resource is an invaluable resource for owners and technicians to ensure the longevity and optimal performance of their Grizzly 125.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Grizzly 125

Year:

Product Type:

Service Repair Manual

👋 Introduction

Market Position

Target User:

Enthusiast owners and independent repair shops seeking to maintain and repair the Yamaha Grizzly 125.

Value Proposition:

Provides factory-level repair information to save on dealership service costs and ensure proper maintenance.

Competitive Analysis

Competitors Addressed:

Addresses common maintenance and repair needs, offering a superior alternative to generic repair guides.

Key Features

Feature Highlight:

Clickable index drastically improves usability and reduces diagnostic time.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair for the 2004 Yamaha Grizzly 125 ATV.

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures.

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel pump, fuel lines, and tank maintenance.

Transmission Drivetrain:

Automatic Continuously Variable Transmission (CVT) belt inspection/replacement, clutch service, gearbox lubrication, and rear differential maintenance.

Cooling System:

Radiator, fan, coolant, and thermostat testing and service.

Electrical System:

Ignition system troubleshooting, battery maintenance, charging system (stator, regulator/rectifier), lighting, and wiring diagrams.

Brake System:

Front and rear brake caliper service, master cylinder, brake lines, pad replacement, and bleeding procedures.

Suspension Steering:

Front and rear suspension component inspection, shock absorber service, steering linkage, tie rods, and wheel alignment.

Chassis Frame:

Frame inspection, bodywork removal/installation, and fastener torque specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug servicing, air filter cleaning/replacement, chain adjustment (if applicable), and general inspection points.

Troubleshooting:

Diagnostic charts and procedures for common starting, running, and electrical issues.

Engine Rebuild:

Detailed steps for piston replacement, cylinder head service, valve adjustments, and crankshaft/connecting rod checks.

Carburetor Rebuild:

Step-by-step instructions for disassembling, cleaning, and reassembling the carburetor with specific jetting and adjustment data.

Electrical Diagnostics:

Testing of sensors, switches, coils, and diagnostic procedures using multimeters.

Brake Overhaul:

Complete brake system service, including bleeding and component replacement.

Technical Depth

Depth Level:

Comprehensive; covers everything from basic scheduled maintenance to complete engine and component overhauls.

Diagnostic Capabilities:

Advanced diagnostic procedures, including electrical testing and troubleshooting charts.

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Printability:

Printable pages for workshop use.

Navigation:

Click-able index for easy navigation.

Print Quality

Image Resolution:

High-resolution images and diagrams.

Binding Type

Binding Method:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, SOHC, 4-stroke

Displacement:

124 cc

Bore X Stroke:

52.0 mm x 57.4 mm

Compression Ratio:

10.0:1

Valve Clearance Intake Cold:

0.08 - 0.13 mm (0.003 - 0.005 in)

Valve Clearance Exhaust Cold:

0.13 - 0.18 mm (0.005 - 0.007 in)

Performance

Horsepower Estimate:

~8.5 HP @ 7500 RPM

Torque Estimate:

~7.0 lb-ft @ 6000 RPM

Fuel System

Fuel Delivery:

Carburetor (Teikei Y24P)

Carburetor Idle Speed:

1400 ± 100 RPM

Fuel Type:

Unleaded gasoline (87 octane or higher recommended)

Fuel Tank Capacity:

2.3 L (0.6 US gal)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

Shaft Drive

Transmission Fluid Type:

Yamaha Genuine Gear Oil (or equivalent API GL-4, SAE 80W-90)

Features

Gearbox Ratio:

Refer to manual for specific ratios and CVT ratios.

📐 Dimensions

Exterior

Length:

1790 mm (70.5 in)

Width:

1005 mm (39.6 in)

Height:

1045 mm (41.1 in)

Wheelbase:

1205 mm (47.4 in)

Weights

Curb Weight:

167 kg (368 lbs)

Maximum Towing Capacity:

N/A (not specified for this model)

Maximum Rack Load Front:

20 kg (44 lbs)

Maximum Rack Load Rear:

40 kg (88 lbs)

🛡️ Safety Features

Ratings

Atv Classification:

Utility ATV

Active Features

Braking System:

Front: Dual hydraulic disc; Rear: Sealed drum brake.

Throttle Limiter:

Adjustable throttle stop screw for speed control.

Passive Features

Lighting:

Halogen headlights and taillight.

Ignition Override:

Key ignition system.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility vehicle)

Driver Assistance

Assistance Features:

N/A (Basic utility vehicle)

Connectivity

Connectivity Options:

N/A (Basic utility vehicle)

🔧 Maintenance

Service Intervals

Initial Break In Service:

Recommended at 100 km or 10 hours of operation (refer to manual for specifics).

Engine Oil Change:

Every 1000 km or 6 months, whichever comes first (or per manual recommendations).

Air Filter Cleaning:

Every 200 km or as needed based on operating conditions.

Spark Plug Replacement:

Check every 1000 km, replace as needed.

Transmission Fluid Change:

Refer to manual for specific intervals, typically annually or at higher mileage.

Fluid Specifications

Engine Oil Type:

Yamaha Genuine Yamalube 4-stroke motorcycle oil (e.g., 10W-40) or equivalent API SG or higher.

Engine Oil Capacity:

0.80 L (0.85 US qt) without filter change; 0.90 L (0.95 US qt) with filter change.

Coolant Type:

Permanent Antifreeze/Coolant (50/50 mix of ethylene glycol and deionized water).

Known Issues

Common Wear Item:

CVT belt wear and potential for slippage under heavy load or prolonged use.

Carburetor Maintenance:

Occasional clogging due to fuel quality or debris, requiring cleaning and adjustment.

Electrical Connections:

Corrosion in electrical connectors, particularly in wet environments, can lead to intermittent faults.

📚 Vehicle History

Brand Heritage

Yamaha Atv Legacy:

Yamaha has a long-standing history of producing reliable and capable ATVs, pioneering many industry features.

Model Evolution

Grizzly Lineage:

The Grizzly line is known for its off-road prowess and utility. The 125 model represents an entry-level option within this esteemed lineup.

Production

Manufacturing Location:

Primarily manufactured in Japan and/or USA by Yamaha Motor Corporation.

🏆 Awards & Recognition

Recognitions

Brand Award History:

Yamaha ATVs consistently receive positive reviews for reliability and performance in their respective classes.

Ratings

Industry Perception:

The Grizzly line is highly regarded for its robust build and off-road capabilities, even in its smaller displacements.

Certifications

Certification Standard:

Manufactured to meet industry safety and emissions standards for ATVs.