Yamaha Grizzly 600 Manual

The Yamaha Grizzly 600 is a powerful all-terrain vehicle (ATV) featuring a 600cc liquid-cooled, 4-stroke engine, Ultramatic automatic transmission with engine braking, On-Command 2WD/4WD with differential lock, independent double wishbone front suspension, IRS rear suspension, disc brakes, electric start, and towing capacity. Below are key sections for safety, features, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Pre-Ride Inspection 3. Controls and Operation 4. Specifications 5. Maintenance Schedule 6. Fluid Capacities 7. Tire Information 8. Storage Procedures 9. Safety Guidelines 10. Warranty Information 11. Troubleshooting

Features at a Glance

Key components: 600cc engine, Ultramatic transmission, On-Command 4WD system, front and rear racks, towing hitch.

Feature	Description
Engine	600cc liquid-cooled, 4-stroke, SOHC
Transmission	Ultramatic automatic with engine braking
Drive System	On-Command 2WD/4WD with differential lock
Suspension	Independent double wishbone front, IRS rear
Brakes	Dual hydraulic disc front, sealed wet brake rear
Fuel Capacity	4.8 gallons (18.2 liters)
Towing Capacity	Up to 1,212 lbs (550 kg)
Front Rack Capacity	88 lbs (40 kg)
Rear Rack Capacity	176 lbs (80 kg)
Electric Start	Standard with backup recoil starter

Pre-Ride Inspection

Always perform these checks before operating the ATV.

Check fuel level: Ensure adequate fuel for your ride.
Inspect tires: Check pressure and condition for damage.
Check fluids: Engine oil, coolant, brake fluid levels.
Test controls: Throttle, brakes, lights, switches.
Verify drive selection: 2WD/4WD lever operation.

WARNING! Never operate an ATV without proper safety gear. Always wear helmet, eye protection, gloves, and boots.

Controls and Operation

Familiarize yourself with all controls before riding.

Starting: Set parking brake, shift to Neutral, turn key ON, press start button.
Driving: Release parking brake, select Forward or Reverse, apply throttle smoothly.
On-Command System: Use lever to select 2WD, 4WD, or 4WD with differential lock.
Braking: Use both front and rear brakes together for controlled stops.
Parking: Apply parking brake on inclines; shift to Park when stopped.

CAUTION! Avoid sudden throttle or brake applications. Practice in open area before challenging terrain.

Specifications

Engine Type: 600cc liquid-cooled, 4-stroke, SOHC.
Bore x Stroke: 92.0mm x 71.8mm.
Compression Ratio: 9.5:1.
Fuel System: Mikuni BSR36 carburetor.
Ignition: DC-CDI.
Transmission: Ultramatic automatic V-belt with all-wheel engine braking.
Final Drive: Shaft.
Suspension Travel Front/Rear: 6.7 in / 7.9 in.
Brakes Front/Rear: Dual hydraulic disc / Sealed wet brake.
Tires Front/Rear: AT25 x 8-12 / AT25 x 10-12.
Overall Length/Width/Height: 81.9 in / 46.5 in / 48.4 in.
Seat Height: 35.6 in.
Ground Clearance: 10.8 in.
Dry Weight: 617 lbs.

Maintenance Schedule

Regular maintenance ensures longevity and safety. Refer to manual for complete schedule.

Item	Every 100 mi	Every 500 mi	Every 1000 mi
Engine Oil	Check	Change	Change
Oil Filter	-	Change	Change
Air Filter	Check	Clean/Replace	Clean/Replace
Spark Plug	-	Inspect	Replace
Brake Pads	Check	Inspect	Replace as needed
Drive Shaft Grease	-	-	Lubricate
Wheel Nuts	Check torque	Check torque	Check torque

Note: Service more frequently under severe conditions (dust, mud, towing).

Fluid Capacities

Use recommended Yamaha fluids or equivalents.

Engine Oil (with filter change): 3.7 qt (3.5 L)
Engine Oil (without filter change): 3.5 qt (3.3 L)
Coolant: 1.85 qt (1.75 L)
Front Differential Oil: 0.42 qt (0.4 L)
Rear Differential Oil: 0.53 qt (0.5 L)
Fuel Tank: 4.8 gal (18.2 L)

WARNING! Dispose of used fluids properly. Do not mix different types of oil or coolant.

Tire Information

Maintain proper tire pressure for optimal handling and tire life.

Recommended Pressure (cold): Front: 3.6 psi (25 kPa), Rear: 3.6 psi (25 kPa)
Maximum Load: See sidewall rating.
Tire Type: AT25 (All-Terrain).

CAUTION! Do not exceed maximum inflation pressure. Check pressure when tires are cold. Inspect for cuts, punctures, and wear.

Storage Procedures

Proper storage prevents damage during periods of non-use.

Clean ATV thoroughly, especially underside.
Change engine oil and filter.
Add fuel stabilizer and run engine for 5 minutes.
Disconnect battery negative terminal or use maintainer.
Inflate tires to recommended pressure; elevate if possible.
Store in cool, dry place, covered with breathable material.

Safety Guidelines

ATVs can be hazardous. Always follow these rules.

Always wear an approved helmet, eye protection, long sleeves, long pants, gloves, and over-the-ankle boots.
Never carry passengers on a single-rider ATV.
Never operate on public roads or paved surfaces.
Never operate under the influence of alcohol or drugs.
Ride only on designated trails at safe speeds for conditions.
Supervise riders under 16; ensure they ride an age/size appropriate ATV.
Complete a training course. For US: ATV Safety Institute (ASI) 1-800-887-2887.

Warranty Information

Yamaha Motor Corporation, U.S.A. provides a limited warranty. See your Yamaha dealer for complete terms.

Warranty Period: 6 months (Limited Factory Warranty).
Emission Control System Warranty: 30 months or specific mileage.
What is Covered: Repair or replacement of defective parts.
Owner's Responsibilities: Proper maintenance, record keeping, using approved parts.

For warranty service, contact an authorized Yamaha ATV dealer. Keep your proof of purchase.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Dead battery, fuel valve off, kill switch	Check battery charge; ensure fuel valve ON; check kill switch position.
Engine stalls	Clogged fuel filter, dirty carburetor	Replace fuel filter; clean carburetor jets.
Loss of power	Clogged air filter, worn drive belt	Clean/replace air filter; inspect drive belt.
Overheating	Low coolant, clogged radiator	Check coolant level; clean radiator fins.
Poor braking	Worn pads, air in lines, low fluid	Replace pads; bleed brakes; check fluid.
4WD not engaging	Faulty actuator, wiring issue	Check actuator operation; inspect wiring harness.
Electrical issues	Blown fuse, loose connection	Check all fuses; inspect wiring connections.

Service: For complex issues, contact an authorized Yamaha dealer.

Support: Yamaha Customer Relations: 1-800-962-7926. www.yamahamotorsports.com