Yamaha Grizzly 600 Service Manual

The Yamaha Grizzly 600 is a rugged, all-terrain vehicle (ATV) designed for work and recreation. This service manual provides comprehensive information for maintenance, troubleshooting, and repair of the Grizzly 600, including the 2WD and 4WD models. It covers the engine, transmission, chassis, electrical system, and periodic maintenance procedures. Below are key sections for specifications, maintenance schedules, component service, troubleshooting, and safety information.

1. Features at a Glance 2. Safety Precautions 3. Periodic Maintenance 4. Specifications 5. Engine Service 6. Transmission & Drivetrain 7. Chassis & Suspension 8. Electrical System 9. Troubleshooting 10. Wiring Diagrams 11. Torque Specifications

Features at a Glance

Key components: 586cc air-cooled, 4-stroke, SOHC engine; Ultramatic automatic transmission with engine braking; On-Command 2WD/4WD system; Independent double-wishbone front suspension; IRS rear suspension.

FeatureDescription
Engine Type4-stroke, SOHC, air-cooled, single cylinder
Displacement586cc
TransmissionAutomatic Ultramatic (V-belt) with High/Low range
Drive SystemOn-Command 2WD/4WD with differential lock
Front SuspensionIndependent double wishbone
Rear SuspensionIndependent Rear Suspension (IRS)
BrakesHydraulic disc brakes (front and rear)
Fuel Capacity4.8 gallons (18.2 liters)
Towing CapacityUp to 1102 lbs (500 kg)
Payload CapacityUp to 330 lbs (150 kg) on cargo rack

Safety Precautions

Always follow safety procedures when servicing the ATV.

  1. Work in a well-ventilated area away from sparks or flames.
  2. Use proper tools and personal protective equipment (gloves, safety glasses).
  3. Support the ATV securely on a stand or lift before working underneath.
  4. Disconnect the battery negative terminal before electrical work.
  5. Allow the engine and exhaust system to cool before servicing.

WARNING! Gasoline is highly flammable. Do not smoke or use open flames. Handle with care.

Periodic Maintenance

Regular maintenance ensures optimal performance and longevity.

  1. Pre-ride inspection: Check tires, brakes, lights, and fluid levels.
  2. Engine oil change: Every 100 hours or 6 months (whichever comes first).
  3. Oil filter: Replace with every oil change.
  4. Air filter: Clean every 50 hours; replace if damaged.
  5. Spark plug: Inspect every 100 hours; replace as needed.
  6. Drive belt: Inspect every 200 hours for wear and cracks.
  7. Brake fluid: Check level and condition every 100 hours.
  8. Differential oil: Change every 200 hours (4WD models).

CAUTION! Use only recommended fluids and parts. Overtightening can damage components.

Specifications

Engine Service

Includes procedures for top end, cylinder head, valve train, and bottom end.

Valve Clearance Adjustment: Intake 0.10–0.15 mm (0.004–0.006 in), Exhaust 0.15–0.20 mm (0.006–0.008 in). Adjust when engine is cold.

Carburetor: Main jet #142.5, Pilot jet #45, Needle jet 5F21-3, Float height 13.5 mm. Clean jets and passages regularly.

Cooling System: Air-cooled; ensure fins are clean and unobstructed.

Transmission & Drivetrain

Ultramatic automatic transmission service and 4WD system maintenance.

  1. Drive belt inspection: Remove cover, check for cracks, fraying, or glazing.
  2. Belt replacement: Loosen engine mounting bolts to relieve tension.
  3. Differential oil: Drain and refill with SAE 80W-90 gear oil (0.35 L).
  4. On-Command system: Check engagement; clean and lubricate linkage.
  5. Front drive shaft: Inspect boots for tears; grease splines periodically.

Tip: Always check belt alignment after service to prevent premature wear.

Chassis & Suspension

Frame, suspension, steering, and brake system service.

  1. Front suspension: Check A-arm bushings and ball joints for play.
  2. Shock absorbers: Inspect for leaks; adjust preload as needed.
  3. Steering: Check for free play; adjust tie rods if necessary.
  4. Brakes: Inspect pads and rotors for wear; bleed system if spongy.
  5. Wheel bearings: Check for roughness; repack or replace as needed.
  6. Tires: Maintain recommended pressure (Front 3.9 psi, Rear 3.9 psi for standard terrain).

WARNING! Always torque suspension and steering nuts/bolts to specification. Loose components can cause loss of control.

Electrical System

Battery, charging system, ignition, and lighting.

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

Charging system: Stator output: 14V AC at 5000 rpm. Regulator/Rectifier: Check for proper DC output (13.5–15V).

Ignition coil resistance: Primary 0.16–0.24 Ω, Secondary 6.5–9.8 kΩ.

Headlight: 12V 30/30W (halogen). Check switch and wiring for continuity.

Troubleshooting

SymptomPossible CauseCorrective Action
Engine won't startWeak battery, faulty spark plug, fuel issueCheck battery voltage; inspect spark plug; verify fuel flow.
Poor performance/loss of powerClogged air filter, dirty carburetor, worn drive beltClean/replace air filter; clean carburetor jets; inspect drive belt.
4WD not engagingFaulty switch, damaged actuator, low differential oilTest switch; check actuator operation; check oil level.
OverheatingLow oil, clogged cooling fins, lean fuel mixtureCheck oil level; clean fins; check carburetor settings.
Brakes dragging or weakContaminated pads, air in lines, worn master cylinderClean or replace pads; bleed brakes; inspect master cylinder.
Electrical accessories not workingBlown fuse, bad connection, faulty switchCheck fuses; inspect wiring harness; test switch continuity.

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

Wiring Diagrams

Refer to separate fold-out pages for complete wiring diagrams. Key systems: Starting & Charging, Ignition, Lighting, 4WD Control.

Color Codes: R=Red, B=Black, W=White, G=Green, Y=Yellow, L=Blue, Br=Brown, Gr=Gray, Lg=Light Green, P=Pink.

Torque Specifications

Note: Apply thread locker where specified. Always use a calibrated torque wrench.

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