1998 Yamaha Grizzly 600, YFM600FWAL/YFM600FWALC ATV Service Manual & Supplements (P/N LIT-11616-12-37, LIT-11616-11-21)

This 1998 Yamaha Grizzly 600 service manual set combines the YFM600FWAK base manual (P/N LIT-11616-11-02), the YFM600FWACK California supplement (P/N LIT-11616-11-21), and the YFM600FWAL/YFM600FWALC supplement (P/N LIT-11616-12-37).

• Engine repair: Engine removal, cylinder head and crankcase disassembly, valve clearance adjustment, piston inspection, camshaft installation, and decompression system checks.

• V-belt transmission: Primary and secondary sheave service, centrifugal and one-way clutch inspection, internal transmission repair, and shift control adjustment.

• Shaft drive: CV joint replacement, differential and final drive service, middle gear shim selection, gear lash adjustment, and gear motor installation.

• Fuel and lubrication: Mikuni BST40 carburetor rebuilding, fuel level adjustment, oil pump inspection, oil cooler routing, and variant-specific carburetor specifications.

• Brakes and chassis: Hydraulic brake bleeding, master cylinder and caliper repair, rear drum brake service, steering checks, toe-in adjustment, and suspension inspection.

• Electrical diagnosis: Ignition, starting, charging, lighting, fan control, and 2WD/4WD tests, with circuit diagrams, connector views, and electrical test specifications.

Yamaha wrote these manuals primarily for its dealers and qualified mechanics, assuming a working knowledge of mechanical principles and machine repair.

Model Differences and Carburetor Service

The supplements distinguish California carburetor calibration from standard settings and update valve, clutch, wheel, suspension, and electrical data. The L-series tables identify USA, California, Canadian, European, and Oceania builds.

Carburetor procedures cover piston valve and coasting enricher diaphragm inspection, needle valve and seat replacement, and float height and fuel level adjustment.

Engine Overhaul and Oil Cooling

Periodic inspection and lubrication schedules cover engine oil, drivetrain components, and brake systems.

The engine chapter gives inspection limits for valve stems, piston-to-cylinder clearance, rocker arms, and crankshaft wear, along with component torque tables, M6/M8 crankcase fastener data, and tightening sequences. Camshaft timing and automatic decompression checks sit alongside recoil starter and CDI magneto service.

The timing chain uses an automatic tensioner, with inspection and installation procedures provided. Lubrication diagrams trace the separate oil pump circuits for engine lubrication and the oil cooler.

Crankcase assembly notes warn that omitting the rubber damper needed for proper oil flow can damage the engine.

V-Belt Transmission and Shaft Drive

Exploded views of the primary and secondary sheaves accompany inspections of pulley weights, torque cams, springs, and guide pins. The manual explains how the one-way clutch provides engine braking and gives checks for clutch operation. The tool list identifies the sheave spring compressor YM-04134 / 90890-04134.

Factory gear lash measurements and shim selection procedures cover differential, middle drive, and final drive setup. The calculations account for marked component dimensions when gears or housings are replaced, helping avoid reusing an unsuitable shim stack.

The shaft drive troubleshooting section warns that insufficient gear lash can damage gear teeth. Differential case and ring gear service is covered, but Yamaha treats the internal differential gear unit as a factory-assembled unit that must not be dismantled.

Brakes, Steering, and Suspension

Front disc-brake repair includes master cylinder and caliper inspection; rear drum brake procedures cover shoes, camshaft, and lever/pedal adjustment. Steering knuckle and wheel bearing replacement are paired with tie-rod and toe-in checks.

The suspension sections address front arm and swingarm service, shock inspection, and rear spring preload adjustment. Cable Routing drawings support hose and harness refitting.

Follow the manual's ATV support and brake system precautions during chassis work.

Electrical Troubleshooting and Circuit Diagrams

Diagnostic charts cover the C.D.I. magneto, pickup/source coils, starter motor, and starter interlocks. Fan troubleshooting includes the relay, circuit breaker, thermo unit, and control unit; the 2WD/4WD section checks the select switch and gear motor.

Ignition System and Electric Starting System circuit diagrams show the related connectors and interlocks. Cooling System and 2WD/4WD Selecting System diagrams accompany their diagnostic charts.

The separate overall YFM600FWA wiring diagram listed in the contents is not included in this PDF.

PDF Contents and Diagram Readability

PDF text search and embedded bookmarks are not available. Small circuit labels require zooming, and some shaded connector and wire code details remain difficult to read. This 353-page PDF contains 319 pages from the base manual (including two nearly blank chapter-end pages), 21 from the L-series supplement, eight from the California supplement, two compilation cover pages, and three repeated seller-agreement pages; all are included in the total.