2001 Yamaha Grizzly 600 Service Manual

The 2001 Yamaha Grizzly 600 is a four-wheel-drive all-terrain vehicle (ATV) powered by a 595cc, liquid-cooled, SOHC, 4-stroke engine with electric start. This comprehensive service manual covers periodic maintenance, troubleshooting, engine overhaul, chassis, electrical system, and transmission service. It is intended for qualified service technicians and provides detailed procedures, specifications, and diagrams for proper repair and maintenance.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine 5. Fuel System 6. Chassis 7. Electrical System 8. Transmission & Drive System 9. Troubleshooting 10. Wiring Diagrams 11. Appendices

General Information

This manual provides safety information, model identification, general specifications, and tools required for servicing the 2001 Yamaha Grizzly 600 ATV.

Item	Description
Model	YFM600FA (Grizzly 600 4x4)
Identification Number	Location: Frame left side
Recommended Fuel	Unleaded gasoline (87 pump octane minimum)
Oil Capacity	Engine: 2.6 qt (2.5 L) with filter change
Coolant Capacity	1.59 qt (1.5 L)
Front/Rear Tire Pressure	3.9 psi (27 kPa) / 3.9 psi (27 kPa)

Specifications

Detailed technical specifications for the 2001 Yamaha Grizzly 600.

Engine Type: 595cc, liquid-cooled, SOHC, 4-stroke, single cylinder.
Bore x Stroke: 92.0 mm x 89.5 mm.
Compression Ratio: 9.5:1.
Starting System: Electric starter with auxiliary recoil.
Lubrication System: Wet sump.
Transmission: 5-speed with reverse, Ultramatic® V-belt automatic.
Drive System: Yamaha On-Command® pushbutton 2WD/4WD with differential lock.
Suspension Front/Rear: Independent double wishbone / Swingarm.
Brakes Front/Rear: Dual hydraulic disc / Sealed wet multi-disc.
Dimensions (LxWxH): 81.9 in x 46.1 in x 47.6 in (2080 mm x 1170 mm x 1210 mm).
Dry Weight: 551 lb (250 kg).

Periodic Maintenance

Maintenance schedule and procedures to ensure optimal performance and longevity.

Pre-ride Inspection: Check tires, brakes, lights, controls, and fluid levels.
Engine Oil: Change every 100 hours or 6 months, whichever comes first.
Oil Filter: Replace with every oil change.
Air Filter: Clean every 20-40 hours; replace if damaged.
Spark Plug: Check/clean every 100 hours; replace per specification.
Drive Belt: Inspect every 200 hours for wear/cracks.
Coolant: Change every 2 years.
Differential Oil (Front/Rear): Change every 200 hours.
Brake Fluid: Inspect level; change every 2 years.
Wheel Nuts & Fasteners: Check torque periodically.

WARNING! Always perform maintenance in a well-ventilated area with the engine off and cool. Support ATV securely on a stand.

Engine

Complete service procedures for the engine assembly, including removal, disassembly, inspection, and reassembly.

Top End: Cylinder head removal, valve adjustment (IN: 0.10–0.15 mm / EX: 0.15–0.20 mm), camshaft inspection.

Cylinder & Piston: Inspection for wear, scoring, or out-of-round. Piston ring end gap specification: 0.15–0.30 mm.

Crankcase & Crankshaft: Splitting the crankcase, connecting rod big-end side clearance, crankshaft runout check.

Lubrication System: Oil pump inspection, pressure relief valve, oil strainer cleaning.

Cooling System: Radiator inspection, thermostat operation check (opens at 71–85°C), water pump impeller inspection.

Fuel System

Service for the carburetor, fuel tank, and related components.

Carburetor: Model: Mikuni BSR36. Disassembly, cleaning, float height adjustment (14.0–16.0 mm), pilot screw setting (initial: 2-1/4 turns out).
Throttle Cable: Check for smooth operation and free play (3–5 mm).
Fuel Valve: Inspect for leaks; clean sediment cup.
Air Induction System: Check AIS hoses and valves for proper operation.

Tip: Use compressed air to clear jets; never use wire to clean.

Chassis

Frame, suspension, steering, and brake system service.

Component	Service Procedure
Front Suspension	Inspect A-arms, bushings, shocks. Recommended sag: 1-2 in (25-50 mm).
Steering	Check bearing play; adjust if loose. Torque steering stem nut: 59 ft-lb (80 Nm).
Front Brakes	Pad wear limit: 0.12 in (3.0 mm). Disc thickness limit: 0.20 in (5.0 mm). Bleed system.
Rear Brake	Adjust lever free play. Inspect sealed drum assembly.
Wheels & Tires	Check for damage/runout. Tire size: Front 25x8-12, Rear 25x10-12.

Electrical System

Battery, charging system, ignition, lighting, and switch testing.

Battery: Type: YTZ7S. Voltage: 12V 6Ah. Specific gravity: 1.280 at 68°F (20°C).
Charging System: Output: 14V 15A @ 5000 rpm. Test stator resistance: 0.6–0.9 Ω.
Ignition System: CDI unit. Spark plug: NGK DR8EA. Gap: 0.028–0.031 in (0.7–0.8 mm).
Starting System: Starter motor draw: < 90A. Solenoid inspection.
Lighting: Headlight: 12V 30/30W. Bulb replacement procedures.

Transmission & Drive System

Ultramatic transmission, drive belt, front and rear differential service.

Drive Belt: Width wear limit: 1.18 in (30 mm). Removal and installation procedure.
Primary/Secondary Clutch: Sheave inspection, roller wear, spring fatigue check.
On-Command 4WD System: Vacuum diaphragm test, actuator operation check.
Front Differential: Oil capacity: 0.26 qt (0.25 L). Gear mesh inspection.
Rear Gearcase: Oil capacity: 0.42 qt (0.40 L). Bearing preload adjustment.

WARNING! The drive belt is under tension; follow manual procedure to safely relieve tension before removal.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine does not start	Fuel, spark, compression	Check fuel valve, spark plug, compression (standard: 142 psi).
Poor performance/loss of power	Clutch, belt, carburetor	Inspect drive belt wear; clean carburetor; check clutch operation.
Overheating	Coolant, thermostat, load	Check coolant level, radiator fins, thermostat operation.
Electrical failure (no lights)	Battery, fuse, wiring	Test battery voltage; check main 30A fuse; inspect for loose connections.
4WD not engaging	Vacuum lines, actuator, switch	Inspect vacuum lines for leaks; test On-Command switch and actuator.
Excessive vibration	Wheels, drive shaft, engine mount	Check tire balance; inspect U-joints and engine mounts.

Wiring Diagrams

Complete color-coded wiring diagrams for the entire electrical system, including main harness, lighting, ignition, and charging circuits. Diagrams show connector locations, wire colors, and ground points for accurate diagnosis.

Appendices

Torque Specifications: Critical fastener torque values (e.g., Cylinder head bolts: 20 ft-lb in sequence). Special Tools: List of Yamaha special tools recommended for service (e.g., flywheel puller, bearing driver set). Lubrication Points: Grease fittings locations and recommended grease type. Storage Preparation: Steps for preparing ATV for long-term storage.

Service Support: For genuine Yamaha parts and technical assistance, contact an authorized Yamaha dealer or visit Yamaha's official website.