Grizzly 600 Service Manual

The Grizzly 600 is a rugged all-terrain vehicle (ATV) designed for both recreational and utility use. This service manual provides comprehensive information for maintenance, troubleshooting, and repair of the Grizzly 600, including engine specifications, chassis details, electrical systems, and periodic maintenance schedules. Below are key sections covering safety, specifications, maintenance procedures, and troubleshooting.

Features at a Glance

Key components: 4-stroke engine, On-Command 4WD system, independent rear suspension, electric start, front and rear racks, towing capacity.

Feature	Description
Engine Type	4-stroke, SOHC, liquid-cooled
Displacement	600cc
Drive System	On-Command 4WD with differential lock
Suspension	Independent double wishbone (front), Independent rear suspension (IRS)
Brakes	Dual hydraulic disc (front), Sealed wet multi-disc brake (rear)
Transmission	Automatic CVT with engine braking
Fuel Capacity	4.8 gallons
Towing Capacity	Up to 1,212 lbs
Front/Rear Racks	Steel construction with cargo capacity ratings
Electric Start	Standard with auxiliary recoil backup

Safety Precautions

Always follow safety guidelines to prevent injury or damage.

1. Read owner's manual before operation.
2. Always wear appropriate safety gear (helmet, eye protection, gloves, boots).
3. Inspect ATV before each use (tires, brakes, lights, fluids).
4. Never operate under the influence of alcohol or drugs.
5. Use on designated trails; avoid paved roads.

WARNING! ATV can be hazardous. Always use proper riding techniques and never exceed load limits. Keep hands and feet inside vehicle while moving.

Specifications

• Model: Grizzly 600.
• Engine: 4-stroke, SOHC, 4-valve, liquid-cooled.
• Bore x Stroke: 92.0 mm x 67.2 mm.
• Compression Ratio: 9.5:1.
• Fuel System: Mikuni BSR36 carburetor.
• Ignition System: DC-CDI.
• Starting System: Electric with auxiliary recoil.
• Transmission: Automatic CVT, V-belt.
• Drive Train: Shaft drive.
• Suspension Travel: Front 6.7 in, Rear 7.5 in.
• Ground Clearance: 10.8 in.
• Dry Weight: 602 lbs.
• Dimensions (LxWxH): 81.9 in x 46.5 in x 48.4 in.

Periodic Maintenance

Follow maintenance schedule to ensure optimal performance and longevity.

Daily/Pre-Ride: Check fuel, oil level, tire pressure, brakes, lights, throttle operation.

Every 100 miles/1 month: Change engine oil and filter, inspect air filter, check drive chain tension, inspect brake pads.

Every 500 miles/6 months: Clean air filter, inspect spark plug, check valve clearance, inspect CVT belt, lubricate chassis points.

Every 1,000 miles/12 months: Change differential oil, inspect wheel bearings, check suspension components, replace brake fluid.

CAUTION! Always use recommended fluids and parts. Allow engine to cool before servicing.

Engine Service

Procedures for engine maintenance and repair.

1. Oil Change: Warm engine, drain oil, replace filter, refill with recommended oil (quantity: 3.7 qt with filter change).
2. Air Filter: Remove side panel, clean foam filter with solvent, re-oil lightly, reinstall.
3. Spark Plug: Gap: 0.028-0.031 in. Replace every 1,000 miles or as needed.
4. Valve Clearance: Check when engine cold. Intake: 0.004-0.006 in, Exhaust: 0.008-0.010 in.
5. Cooling System: Check coolant level, inspect hoses for leaks, replace coolant every 2 years.

Tip: Keep engine area clean to prevent debris from entering air intake.

Chassis & Suspension

Maintenance of frame, suspension, and wheels.

1. Tire Pressure: Front: 3.9 psi, Rear: 3.9 psi (adjust for load/terrain).
2. Wheel Bearings: Inspect for play or noise; repack with grease or replace if worn.
3. Suspension: Check for leaks at shock absorbers; adjust preload as needed.
4. Steering: Inspect tie rods and ball joints for wear; lubricate steering stem bearings.
5. Brakes: Check pad thickness; replace if less than 0.12 in. Bleed hydraulic system if spongy.

WARNING! Always secure ATV on stand before performing chassis work.

Electrical System

Battery, charging, lighting, and starting system.

Battery: 12V, 12Ah. Maintain terminals clean and tight. Charge if voltage below 12.4V.

Charging System: Output: 14V DC at 5,000 rpm. Test stator and regulator/rectifier if battery not charging.

Lights: Headlight: 12V 30/30W. Check bulbs and connections if inoperative.

Starting System: If starter does not engage, check battery, starter relay, and solenoid.

Fuses: Located under seat. Replace with same rating if blown.

Fuel System

Carburetor, fuel tank, and lines.

1. Fuel Tank: Capacity 4.8 gal. Use unleaded gasoline (87 octane minimum).
2. Carburetor: Mikuni BSR36. Clean jets and passages if engine runs poorly.
3. Fuel Filter: Replace annually or if clogged.
4. Fuel Lines: Inspect for cracks or leaks; replace if damaged.
5. Throttle: Ensure smooth operation; adjust cable free play to 0.2-0.3 in.

CAUTION! Work in well-ventilated area; no smoking near fuel system.

Drive System

CVT, drive shaft, and differential.

CVT Belt: Inspect for wear/cracks. Replace if width less than 0.87 in. Clean sheaves with compressed air.

Drive Shaft: Check for damage or leaks at boots. Lubricate U-joints per schedule.

Differential: Change oil every 1,000 miles (capacity: 0.42 qt). Use GL-5 gear oil.

On-Command System: Test 2WD/4WD switching. If not engaging, check vacuum lines and actuator.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Dead battery, fuel issue, spark	Check battery charge; ensure fuel valve ON; inspect spark plug.
Poor performance	Clogged air filter, dirty carburetor	Clean/replace air filter; clean carburetor jets.
Overheating	Low coolant, clogged radiator	Check coolant level; clean radiator fins.
Brakes spongy	Air in lines, worn pads	Bleed brake system; replace pads if worn.
4WD not engaging	Vacuum leak, actuator fault	Inspect vacuum lines; test actuator operation.
Electrical failure	Blown fuse, bad connection	Check fuses; inspect wiring harness for damage.

Reset: Disconnect battery for 10 minutes to reset ECU if experiencing electronic issues.

Warranty & Support

Limited warranty: 6 months for commercial use, 1 year for recreational use from date of purchase. Warranty covers defects in materials/workmanship under normal use. Not covered: normal wear, improper maintenance, accidents, modifications. Keep proof of purchase for warranty claims.

Service: Contact authorized dealer for repairs. For support, call 1-800-661-7433 or visit www.yamaha-motor.com.