1998 Yamaha Grizzly 600 Owners Manual

The 1998 Yamaha Grizzly 600 is a rugged, all-terrain vehicle (ATV) featuring a 595cc liquid-cooled, 4-stroke, SOHC engine with electric start, Ultramatic automatic transmission with engine braking, On-Command 2WD/4WD with differential lock, independent double-wishbone front suspension, and a swingarm rear suspension. This manual provides essential information for safe operation, routine maintenance, specifications, and troubleshooting of your ATV.

1. Features at a Glance 2. Pre-Ride Inspection & Safety 3. Controls and Indicators 4. Specifications 5. Operation Procedures 6. Routine Maintenance 7. Lubrication Points 8. Storage Guidelines 9. Troubleshooting 10. Warranty & Support

Features at a Glance

Key components: Engine, Ultramatic transmission, On-Command 4WD system, suspension, and instrumentation.

Feature	Description
Engine	595cc, liquid-cooled, 4-stroke, SOHC, 4-valve
Starting System	Electric start with auxiliary recoil backup
Transmission	Ultramatic automatic V-belt with all-wheel engine braking
Drive System	On-Command 2WD/4WD with differential lock
Front Suspension	Independent double wishbone, 6.7" travel
Rear Suspension	Swingarm with single shock, 7.1" travel
Brakes	Dual hydraulic disc front, sealed wet multi-disc rear
Fuel Capacity	4.8 gallons (18.2 liters)
Instrumentation	Speedometer, odometer, tripmeter, fuel gauge, 4WD indicator
Towing Capacity	Up to 850 lbs with optional hitch

Pre-Ride Inspection & Safety

Always perform a pre-ride inspection to ensure safe operation.

Check fuel level and ensure there are no leaks.
Inspect tires for proper pressure and damage (Front: 3.9 psi, Rear: 3.9 psi).
Test brakes for proper function and check fluid levels.
Check throttle lever for smooth operation and full return.
Verify all lights and indicators are working.
Ensure oil level is within the specified range.

WARNING! Always wear an approved helmet, eye protection, gloves, boots, and protective clothing. Never operate under the influence of drugs or alcohol. This ATV is designed for operator use only; no passengers.

Controls and Indicators

Familiarize yourself with all controls before starting the engine.

Left Handlebar: Headlight Dimmer Switch, Turn Signal Switch, Horn Button, 2WD/4WD/Differential Lock Switch, Light Switch.

Right Handlebar: Electric Start Button, Engine Stop Switch, Throttle Lever, Front Brake Lever.

Instrument Panel: Speedometer, Odometer, Tripmeter, Fuel Gauge, 4WD Indicator Light, Neutral Indicator Light, Reverse Indicator Light, High-Temp Warning Light.

Other Controls: Parking Brake Lever, Shift Lever (F-N-R), Fuel Valve, Choke Knob.

Specifications

Model: YFM600FA Grizzly 600
Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve
Displacement: 595cc
Bore x Stroke: 92.0mm x 89.5mm
Compression Ratio: 9.0:1
Fuel System: Mikuni BSR36 carburetor
Ignition System: DC-CDI
Transmission: Ultramatic automatic V-belt, H, L, N, R, P
Drive Train: Shaft drive, On-Command 2WD/4WD with diff lock
Suspension Front/Rear: Independent double wishbone / Swingarm
Brakes Front/Rear: Dual hydraulic disc / Sealed wet multi-disc
Tires Front/Rear: AT25 x 8-12 / AT25 x 10-12
Dimensions (LxWxH): 81.9" x 46.1" x 47.6"
Dry Weight: 595 lbs

Operation Procedures

Starting, riding, and stopping your Grizzly 600.

Starting: Turn fuel valve ON. Pull choke knob if engine is cold. Set parking brake. Shift lever to NEUTRAL (N). Turn ignition key ON. Press the engine stop switch to RUN. Press the electric start button.
Driving: Release parking brake. Select Forward (F) or Reverse (R). Apply throttle smoothly to accelerate. The Ultramatic transmission will automatically adjust.
Using 4WD: Use the On-Command switch to select 2WD or 4WD. Engage differential lock only when needed for extreme traction and at low speeds.
Stopping: Release throttle, apply brakes evenly. Shift to NEUTRAL (N) when stopped. Engage parking brake on inclines.

Tip: Allow the engine to warm up for 2-3 minutes before riding, especially in cold weather.

Routine Maintenance

Follow the maintenance schedule to ensure reliability and longevity.

Item	Interval (miles/hours)	Action
Engine Oil & Filter	First 20 mi, then every 100 mi / 6 mo	Change oil and replace filter
Air Filter	Every 200 mi / 12 mo	Clean foam element, re-oil
Spark Plug	Every 200 mi	Inspect and clean, replace if necessary
Front & Rear Brakes	Every 400 mi	Check pad thickness, fluid level
Drive Shaft Oil	Every 600 mi	Check and change oil
Wheel Nuts/Bolts	Before every ride	Check for tightness
Throttle Cable Freeplay	Every 100 mi	Adjust to 0.2-0.3" freeplay

Lubrication Points

Regular lubrication is critical for smooth operation and preventing wear.

Steering Stem Bearings: Grease every 200 miles or 12 months.
Swingarm Pivot: Grease every 200 miles or 12 months.
Drive Shaft Splines: Apply grease during oil changes.
Brake and Clutch Levers: Light oil at pivot points monthly.
Cables (Throttle, Choke): Lightly oil inner cable periodically.

CAUTION! Use only recommended Yamaha lubricants or equivalents. Over-greasing can attract dirt.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

Change the engine oil and filter.
Add fuel stabilizer to a full tank of gas and run the engine for 5 minutes.
Remove the spark plug, add a teaspoon of oil into the cylinder, and crank the engine slowly. Reinstall the plug.
Clean the ATV thoroughly and apply a light coat of wax to painted surfaces.
Inflate tires to recommended pressure and store on blocks to keep weight off tires.
Disconnect the battery negative (-) terminal and store the battery in a cool, dry place.
Store in a cool, dry place and cover with a breathable cover.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel valve off, dead battery, clogged fuel line	Check fuel valve, charge/replace battery, inspect fuel line and filter.
Engine starts but dies	Choke not adjusted, dirty carburetor	Adjust choke for temperature, clean carburetor jets.
Loss of power	Dirty air filter, clogged spark arrestor	Clean air filter, remove and clean spark arrestor in muffler.
Poor braking	Worn pads, air in lines, low fluid	Replace brake pads, bleed brake lines, refill brake fluid.
4WD not engaging	Faulty switch, vacuum line issue	Check On-Command switch and electrical connections. Inspect vacuum lines for cracks.
Unusual noise from drive train	Low gear oil, worn U-joints	Check and fill gear oil in front and rear differentials. Inspect U-joints for wear.

Reset: For electronic issues, disconnecting the battery for 5 minutes may reset the system.

Warranty & Support

Yamaha Motor Corporation, U.S.A. provides a limited warranty. Refer to your separate warranty booklet for specific terms and conditions. Always use genuine Yamaha parts for repairs to maintain warranty coverage and optimal performance.

Service: For technical support, service locations, or to order parts, contact Yamaha Customer Relations at 1-800-962-7926 or visit www.yamahamotorsports.com.