1998–2001 Yamaha Grizzly 600, YFM600F ATV Service Manual (P/N 11616-11-02)

This Yamaha service manual covers the 1998–2001 Grizzly 600 YFM600F ATV, combining the 4WV1/4WV2 base-manual material with specification supplements for 5GT1–5GT5 and 4WV3. Identification pages show the frame VIN and model-label locations.

• Engine repair: Engine removal and overhaul, valve and piston inspection, cam timing, crankshaft and balancer installation, and oil-pump service.

• V-belt transmission: Primary and secondary sheave service, centrifugal and one-way clutch checks, high/low/reverse transmission inspection, and shift-control adjustments.

• Mikuni BST40 carburetor: Removal, diaphragm and jet inspection, reassembly, fuel-level adjustment, and regional carburetor specification tables.

• Shaft drive: Constant velocity (CV) joint and universal-joint service, middle-drive shaft work, differential checks, and final-drive shim selection and backlash adjustment.

• Brakes and chassis: Hydraulic front-brake bleeding and caliper repair, rear drum-brake service, steering-knuckle inspection, and swingarm and shock-absorber removal.

• Electrical troubleshooting: Ignition, starter, charging, lighting, fan-control, and 2WD/4WD fault tracing, supported by circuit diagrams and component tests.

Suited to mechanics familiar with ATV engine and drivetrain repair, with access to measuring equipment, a press, and the specified service tools.

Engine Overhaul and Carburetor Variants

Periodic-maintenance schedules sit alongside compression testing, valve adjustment, wear limits, and component torque tables. Cylinder-head tightening instructions specify a staged sequence; crankcase tightening views, engine lubrication charts, and exploded assemblies support reassembly.

Recoil-starter rebuilding and CDI-magneto removal are covered along with auto-decompression checks. The crankcase instructions identify an oil-flow damper whose omission can damage the engine.

Regional specifications: The 5GT supplement distinguishes U.S., California, Canadian, European, and Oceanian configurations, including regional carburetor settings and revised chassis and electrical data. The 4WV3 addendum supplies a separate carburetor specification table.

Sheaves, Differential, and Final Drive

The secondary-sheave procedure specifies spring compressor YM-04134 / 90890-04134 and fixed block YM-04135 / 90890-04135.

Shim-selection formulas and separate differential and final-drive backlash procedures help a shop match gear position and clearance after component replacement. The differential section covers the ring gear, housing, bearings, and operating checks, but the factory-assembled internal differential unit must not be dismantled; disassembly can cause malfunction.

Installation gap: Printed page 4-81 is missing from the middle-gear section, interrupting the middle-driven-shaft installation instructions.

Brake, Steering, and Suspension Work

Front master-cylinder and caliper sections provide inspection, seal-replacement, and bleeding information. Rear-brake coverage addresses shoes, the drum, and control adjustment; steering procedures include tie rods, wheel bearings, toe-in, and steering knuckles.

Shock-absorber procedures cover removal, inspection, adjustment, and replacement of complete assemblies. Swingarm service includes pivot bearings and shafts. Brake and suspension work requires secure vehicle support and the manual's safety precautions.

Electrical Tests and Circuit Diagrams

Diagnostic charts trace no-spark and no-crank faults through coils, relays, switches, and wiring. Cooling-system diagnosis addresses the oil-cooler fan, relay, control unit, and thermo unit; 2WD/4WD checks include the gear motor.

Circuit diagrams cover systems including ignition and electric starting, while cable-routing views locate harnesses and hoses. The lighting-system circuit-diagram page, printed 8-22, is missing, although the lighting-system troubleshooting and circuit tests remain included.

Valve-Clearance and Gear-Lash Examples

The following values are a small selection of the engine and shaft-drive adjustment data in the manual.

Cold valve clearance is listed as 0.05–0.10 mm for the intake valves and 0.12–0.17 mm for the exhaust valves, alongside the maintenance chapter's checking and adjustment procedure.

Front differential gear lash is specified at 0.05–0.25 mm; rear final gear lash is 0.1–0.2 mm. Each has its own measurement procedure and shim-adjustment guidance.

PDF Navigation and Included Pages

Search, bookmarks, and diagram detail: OCR text search works across the text chapters; small wiring labels are not reliably searchable. Bookmarks cover the main chapters and 5GT supplement, with no dedicated entry for the 4WV3 addendum. Small wiring labels require zooming, and some shaded areas remain difficult to read.

One printable PDF download contains 336 pages: 314 pages of base-manual material, an 18-page 5GT supplement, and a 4-page 4WV3 addendum. These totals already include the contents, symbol and usage-guide pages, and two blank divider pages.