1998–2001 Yamaha Grizzly 600 YFM600 Factory Service Manual (P/N LIT-11626-14-06)

This three-PDF set of Yamaha factory publications covers the Grizzly 600 YFM600FWA family at two distinct levels: workshop repair information for the K and L builds, plus operator and routine-maintenance material for the N build. The owner volumes suit operators handling routine inspection and maintenance; the service volume is written primarily for Yamaha dealers and qualified mechanics and assumes basic machine-repair knowledge plus the specified tools.

• 882 PDF pages total: a 346-page service PDF, a 375-page English/French/Spanish owner's manual, and a 161-page U.S. owner's manual.
• Document identification: Yamaha manual 5GT-28199-62; U.S. owner's manual P/N LIT-11626-14-06 with cover code 5GT-28199-12; and service publications LIT-11616-11-02, LIT-11616-11-21, and LIT-11616-12-37 under service-set cover code LIT-11616-FW-00.
• Covered factory designations: YFM600FWAK (4WV1 U.S. and 4WV2 Canada), YFM600FWACK/4WV3 California, and YFM600FWAL/YFM600FWALC (5GT1 U.S., 5GT2 California, 5GT3 Canada, 5GT4 Europe, and 5GT5 Oceania). The owner documents identify YFM600FWA(N) and YFM600FWAN(C).
• Engine and transmission repair includes engine removal, cylinder head and valve service, piston inspection, crankcase separation, crankshaft and transmission work, oil-pump inspection, recoil-starter and CDI-magneto service, plus primary/secondary sheave and centrifugal-clutch disassembly and assembly.
• Shaft-drive procedures cover CV joints, universal joints, the front differential, rear axle, final drive, drive shafts, bearing service, gear positioning and shim selection, gear-lash measurement and adjustment, and final operating checks.
• Chassis work reaches beyond routine maintenance into front master-cylinder and caliper repair, rear drum-brake service, hydraulic brake bleeding, steering-stem and knuckle inspection, tie rods, front arms, shock absorbers, swingarm, wheel hubs, and toe-in adjustment.
• Electrical diagnosis provides circuit-based troubleshooting for ignition, electric starting, charging, lighting, signal, oil-cooler fan, and 2WD/4WD selection systems, with switch continuity tests, component checks, and system-specific circuit diagrams.

Repair Depth and Factory Tooling

The service manual explains power flow through the centrifugal clutch, one-way clutch, primary and secondary sheaves, transmission, and On-Command 4WD gear motor before moving into component procedures. Removal and disassembly sections open with exploded views and job charts, followed by inspection, assembly, installation, and adjustment material where needed.

The special-tool section gives both North American and 90890-series numbers. Representative equipment includes the YM-04134 / 90890-04134 sheave spring compressor, YU-01135-A / 90890-01135 crankcase separating tool, YM-01231 / 90890-01231 gear-lash measurement tool, YM-04062 / 90890-04062 universal-joint holder, and YU-03112 / 90890-03112 pocket tester. Related tables supply component-specific torque data, fluid and lubricant requirements, clearances, wear limits, carburetor settings, and electrical test specifications.

The driveline material warns that insufficient gear lash after reassembly is extremely destructive to gear teeth, and it treats the internal differential gear unit as a factory-assembled component that should not be split. In the front-brake repair section, Yamaha specifies new brake fluid for cleaning internal components because ordinary solvents swell and distort the seals.

Variant Data, Diagrams, and Owner Information

The service PDF combines the April 1997 first-edition YFM600FWAK base manual, the July 1997 K California supplement, and the September 1998 L/L California supplement. The L-model volume is a data update for the 5GT regional builds, adding revised general, engine, chassis, and electrical specifications together with lubrication and cable-routing diagrams. The K California supplement supplies the 4WV3 model and carburetor differences and is expressly used with the base manual. Visual references include the lubrication diagrams, cable-routing views, middle-drive shim-selection and final-drive gear-positioning drawings, the shaft-drive troubleshooting chart, system-specific electrical circuit diagrams, and exploded clutch and engine views.

Both owner manuals are first editions dated April 2000. They cover machine identification, main and handlebar controls, the drive-select lever, recoil starting, fuel and choke operation, pre-operation checks, loading, riding techniques, periodic maintenance, troubleshooting, specifications, and warning-label locations. The trilingual 5GT-28199-62 edition presents 11 numbered chapters in English, French, and Spanish. The U.S. YFM600FWAN(C) edition adds noise-regulation, maintenance-record, limited-warranty, and Yamaha Extended Service sections.

There is no separate YFM600FWAM service supplement in this set. The service contents also name a full YFM600FWA wiring-diagram foldout, but that foldout is not included in the 346-page scan; the individual electrical-system circuit diagrams are present. Because the repair material covers spring-loaded sheaves, fuel-system work, hydraulic brakes, and critical shaft-drive setup, Yamaha's warnings and specified tooling should be followed, with qualified service help used when the required knowledge or equipment is unavailable.