Yamaha Grizzly 600 Repair Manual

The Yamaha Grizzly 600 is a powerful all-terrain vehicle (ATV) featuring a 600cc liquid-cooled engine, automatic transmission with selectable 2WD/4WD, independent rear suspension, electric start, and comprehensive safety features. This manual provides detailed repair, maintenance, and troubleshooting procedures for owners and technicians. Below are key sections covering specifications, maintenance schedules, engine repair, transmission service, electrical systems, troubleshooting, and safety information.

Features at a Glance

Key components: 600cc liquid-cooled 4-stroke engine, Ultramatic automatic transmission, On-Command 2WD/4WD system, independent rear suspension, front and rear hydraulic disc brakes, electric start, and comprehensive instrumentation.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity. Follow this schedule based on operating hours or mileage.

1. Daily/Pre-ride: Check tire pressure, brake operation, lights, fluid levels.
2. First 20 hours: Change engine oil and filter, check valve clearance.
3. Every 100 hours: Change engine oil and filter, clean air filter, inspect spark plug.
4. Every 200 hours: Change transmission fluid, inspect brake pads, check wheel bearings.
5. Every 500 hours: Replace air filter element, inspect drive belt, check suspension components.

WARNING! Always perform maintenance with engine off and cool. Use proper safety equipment.

Engine Repair

Detailed procedures for engine disassembly, inspection, and reassembly.

1. Remove engine: Disconnect battery, drain fluids, remove mounting bolts.
2. Cylinder head: Remove camshaft, check valve clearance (intake: 0.10–0.15 mm, exhaust: 0.15–0.20 mm).
3. Piston and cylinder: Inspect for wear, measure cylinder bore (standard: 92.00–92.01 mm).
4. Crankshaft and bearings: Check runout (limit: 0.03 mm), replace if out of specification.
5. Reassembly: Use new gaskets, torque bolts to specification (cylinder head: 40 Nm).

CAUTION! Label all parts during disassembly. Use factory service manual for torque specifications.

Specifications

• Engine Type: 600cc liquid-cooled, 4-stroke, SOHC, 4-valve.
• Bore x Stroke: 92.0 mm x 90.0 mm.
• Compression Ratio: 9.5:1.
• Fuel System: Mikuni BSR36 carburetor.
• Ignition System: DC-CDI.
• Transmission: Ultramatic automatic V-belt with high/low range and reverse.
• Drive System: On-Command 2WD/4WD with differential lock.
• Suspension Travel: Front: 6.7 in (170 mm), Rear: 7.1 in (180 mm).
• Brakes: Hydraulic disc, front dual piston, rear single piston.
• Tires: Front: 25x8-12, Rear: 25x10-12.
• Dry Weight: 600 lbs (272 kg).

Transmission & Drivetrain

Service procedures for Ultramatic transmission and drivetrain components.

Transmission Fluid: Change every 200 hours using Yamaha Hypoid Gear Oil SAE 80W-90 (1.1 liters).

Drive Belt: Inspect for cracks/wear every 500 hours. Replace if width is less than 28.5 mm.

Front Differential: Check oil level every 100 hours. Use SAE 80W-90 gear oil (0.35 liters).

Rear Axle: Inspect for leaks, check axle nut torque (180 Nm).

Electrical System

Diagnosis and repair of electrical components.

1. Battery: Check voltage (12.8V fully charged), clean terminals, secure connections.
2. Charging System: Test stator output (AC voltage 50V+ at 5000 RPM), check regulator/rectifier.
3. Starting System: Test starter motor draw (less than 150A), inspect solenoid contacts.
4. Lighting: Check bulb condition, test switches, inspect wiring harness for damage.

Tip: Use multimeter for diagnosis. Refer to wiring diagram in manual.

Brake System

Maintenance and repair of hydraulic disc brakes.

1. Brake Fluid: Check level in reservoirs, change every 2 years using DOT 4 fluid.
2. Brake Pads: Replace if thickness is less than 1.0 mm.
3. Brake Discs: Measure thickness (front: min 3.5 mm, rear: min 4.0 mm).
4. Bleeding: Use proper sequence (rear then front) to remove air from system.

WARNING! Do not allow brake fluid to contact painted surfaces. Wear eye protection.

Suspension & Steering

Inspection and service of suspension and steering components.

Front Suspension: Check A-arm bushings, ball joints, and shock absorber for leaks.

Rear Suspension: Inspect swingarm pivot bearings, check shock preload adjustment.

Steering: Check handlebar alignment, inspect tie rod ends for play, lubricate steering stem bearings.

Safety Precautions

Always wear helmet, eye protection, gloves, and boots. Never operate under influence of drugs/alcohol. Follow all local ATV laws and regulations.

CAUTION! Always use proper lifting equipment. Secure ATV on stand before working underneath.

Regulatory Information

This ATV complies with EPA and CARB emissions standards. Designed for off-road use only by operators 16 years and older. Always follow manufacturer's guidelines for safe operation. For technical support, contact Yamaha Motor Corporation at 1-800-962-7926 or visit www.yamahamotorsports.com.

Troubleshooting

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

Service: 1-800-962-7926; www.yamahamotorsports.com