Yamaha Grizzly 600 Parts Manual

The Yamaha Grizzly 600 is a rugged all-terrain vehicle (ATV) designed for off-road performance and reliability. This parts manual provides comprehensive information on components, part numbers, assembly diagrams, maintenance procedures, and troubleshooting for the Grizzly 600 model. Below are key sections covering identification, engine, chassis, electrical systems, maintenance schedules, and ordering information.

Model Identification & Specifications

Identify your Yamaha Grizzly 600 using the Vehicle Identification Number (VIN) and model code located on the frame. Key specifications include engine type, dimensions, weight, and capacities.

Engine Assembly & Components

Complete breakdown of engine parts including cylinder head, piston, crankshaft, camshaft, and valve train components with part numbers.

1. Cylinder Head Assembly: Includes head cover, camshaft, valves, springs, and seals.
2. Cylinder & Piston: Cylinder liner, piston, piston rings, wrist pin, and clips.
3. Crankcase & Crankshaft: Crankcase halves, crankshaft assembly, connecting rod, and bearings.
4. Lubrication System: Oil pump, strainer, oil cooler, and related gaskets.
5. Cooling System: Water pump, thermostat, radiator, and hoses.

WARNING! Engine disassembly requires specialized tools and technical knowledge. Refer to service manual for procedures.

Chassis & Suspension Parts

Frame, suspension components, steering, and wheel parts for the Grizzly 600.

1. Frame Assembly: Main frame, subframe, and mounting brackets.
2. Front Suspension: A-arms, shock absorbers, bushings, and ball joints.
3. Rear Suspension: Swingarm, rear shock, linkage, and bearings.
4. Steering System: Steering shaft, handlebars, tie rods, and steering stem bearings.
5. Wheels & Tires: Wheel rims, hubs, bearings, and standard tire specifications.

CAUTION! Inspect suspension components regularly for wear or damage, especially after rough terrain use.

Drive Train Components

• Transmission: Ultramatic V-belt drive with forward, neutral, reverse, and park.
• Drive Belt: Yamaha part number for replacement belt.
• Primary & Secondary Clutches: Sheaves, weights, springs, and related components.
• Drive Shaft: Front and rear drive shafts with U-joints.
• Differential: Front and rear differential assemblies, gears, and seals.
• Final Drive: Sprockets, chain (or shaft drive depending on model year), and tensioners.

Electrical System Parts

Wiring harness, battery, starter, alternator, switches, sensors, and lighting components.

Main Components: Battery (12V, maintenance-free), starter motor, starter relay, voltage regulator/rectifier, CDI unit, ignition coil, spark plug.

Lighting: Headlight assembly, tail/brake light, indicator lights, and wiring connectors. Switches: Handlebar controls (start, light, AWD, differential lock), kill switch, key switch. Sensors: Oil pressure, coolant temperature, throttle position.

Fuel & Exhaust System

Fuel tank, fuel pump (if applicable), carburetor, air intake, and exhaust components.

1. Turn off fuel valve and disconnect battery before servicing fuel system.
2. Fuel Tank: Tank assembly, cap, fuel valve, and mounting hardware.
3. Carburetor: Complete rebuild kit parts including jets, needle, float, and gaskets.
4. Air Intake: Air box, filter, intake hose, and clamps.
5. Exhaust System: Exhaust pipe, muffler, heat shield, and mounting brackets.

Tip: Always use genuine Yamaha air filters and fuel system components for optimal performance.

Brake System Components

Hydraulic disc brake systems front and rear with parking brake mechanism.

1. Front Brakes: Brake calipers, pads, rotors, brake lines, and master cylinder.
2. Rear Brakes: Rear brake caliper, pads, rotor, and associated hardware.
3. Parking Brake: Lever, cable, and rear brake engagement mechanism.
4. Hydraulic Components: Brake fluid reservoir, lines, and bleed valves.
5. Wear Indicators: Specifications for minimum pad thickness and rotor wear limits.

WARNING! Brake fluid is hygroscopic; replace periodically. Use only recommended DOT 4 brake fluid.

Body & Accessories

Plastic body panels, seat, racks, storage, and genuine Yamaha accessories.

Body Panels: Front fender, rear fender, side panels, and mounting hardware. Seat: Seat assembly, latch, and hinges. Racks: Front and rear cargo racks with tie-down points. Accessories: Winch mounting kits, plow systems, cargo boxes, and auxiliary lighting approved for Grizzly 600.

Maintenance Schedule

Recommended service intervals for inspection, adjustment, and replacement of parts.

Initial Service (100 mi/160 km): Check all fasteners, change engine oil and filter, inspect brakes.

Every 300 mi/500 km: Clean air filter, check tire pressure, inspect drive belt.

Every 600 mi/1000 km: Change engine oil and filter, check valve clearance, inspect brake pads.

Every 1200 mi/2000 km: Change differential oil, inspect wheel bearings, check suspension bolts.

CAUTION! Adhere to maintenance schedule to ensure longevity and safe operation.

Exploded View Diagrams

Numbered diagrams showing part relationships and assembly order for major systems.

Note: Part numbers correspond to numbers in diagrams. Use with parts list for ordering.

Troubleshooting & Service Tips

Ordering Parts: Use genuine Yamaha part numbers from this manual. Contact an authorized Yamaha dealer or visit Yamaha's official parts website.

Service Support: For technical assistance, contact Yamaha Customer Support or refer to the full Service Manual (sold separately).