1998–2005 Yamaha YFM600FWA Grizzly 600 ATV Service Manual Set

The main manual provides the workshop procedures, while the supplements add California carburetor specifications and revised regional data, lubrication diagrams, and cable routing. Match the specification section to the ATV’s model code before selecting service data.

Missing material: Printed page 4-81 in the middle-driven-shaft section and page 8-22, the lighting-system circuit diagram, are absent. The separate full-vehicle wiring sheet listed in the contents is also absent; other system circuit diagrams are included.

PDF Search, Bookmarks and Diagram Detail

Text and wiring detail: Body text is searchable through an OCR text layer, although diagram labels are not reliably searchable. Chapter bookmarks are available, but two publication-level bookmarks return to the first page. Small wiring labels require zooming, and some remain difficult to read against shaded backgrounds.

One printable English PDF contains 336 pages across the three publications. The totals above already include 18 front-matter pages and two chapter-divider pages.

Engine, Belt Drive and On-Command 4WD Service

The following selected coverage highlights show the main workshop areas rather than reproduce the full contents. Other topics include recoil-starter rebuilding and headlight adjustment.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head and valve work, piston inspection, crankcase separation, and crankshaft installation.

• CVT and clutch: Primary and secondary sheave disassembly, V-belt inspection, centrifugal-clutch service, and one-way-clutch operation checks.

• Carburetion: Mikuni BST40 removal, diaphragm and jet inspection, carburetor assembly, and float-height and fuel-level adjustment procedures.

• Shaft drive and 4WD: CV-joint service, differential and final-drive inspection, shim selection, backlash adjustment, and On-Command gear-motor checks.

• Brakes and chassis: Front master-cylinder and caliper repair, hydraulic bleeding, rear drum-brake service, steering inspection, and swingarm work.

• Electrical diagnosis: Ignition, starting, charging, signal, cooling-fan, and 2WD/4WD troubleshooting charts with circuit diagrams and component test specifications.

This material is suited to technicians familiar with engine and electrical diagnosis; internal repairs call for precision measuring equipment and the specified service tools.

Engine Inspection and Lubrication

Cylinder and piston inspection distinguishes standard dimensions from wear limits, while the valve sections cover guide replacement, seat inspection, lapping, and spring checks. Camshaft installation includes decompressor alignment and staged cylinder-head tightening sequences to control warpage.

The lubrication material goes beyond capacity listings. The Lubrication Chart and Lubrication Diagrams show the oil paths, and the engine chapter covers pump disassembly, rotor inspection, strainers, and oil-delivery passages.

A specific crankcase assembly caution concerns the rubber damper in the oil circuit: incorrect assembly can interrupt oil flow and damage the engine.

CVT, Carburetor and Shaft-Drive Work

Sheave service: The secondary-sheave procedures identify spring compressor YM-04134 / 90890-04134 and the associated holding equipment. Inspection covers pulley weights, sliding surfaces, guide pins, and torque-cam grooves.

Regional carburetor data: The California supplement changes carburetor identification and jet specifications, while the FWAL/FWALC supplement supplies further revised settings. These distinctions matter when matching parts and adjustment data to the covered variant.

Gear setup: Middle-gear and final-drive sections include shim calculations, backlash measurement, and bearing work. Gear-lash tool YM-01231 / 90890-01231 is identified for the relevant measurements.

The differential chapter covers housing and ring-gear work, but the factory-assembled internal differential unit is not intended for disassembly; the manual warns that dismantling it can cause malfunction.

Electrical Fault Tracing and Chassis Repair

The test charts connect symptoms to component checks, helping distinguish wiring or switch faults from failed electrical assemblies before replacement decisions are made. Examples include no-spark diagnosis, starter-interlock checks, cooling-fan faults, and gear-motor operation.

Illustrated references include the Ignition System Circuit Diagram, Electric Starting System Circuit Diagram, Charging System Circuit Diagram, Signal System Circuit Diagram, 2WD/4WD Selecting System Circuit Diagram, and lubrication-flow drawings.

Chassis procedures extend to steering-stem bearings, tie-rods, front arms, and swingarm pivots. Follow the manual’s vehicle-support and brake-bleeding precautions when carrying out this work.

Examples of Engine Inspection and Final-Drive Specifications

The cylinder-and-piston inspection section specifies piston-to-cylinder clearance of 0.045–0.065 mm, with a 0.15 mm service limit. Spark-plug inspection specifies a 0.8–0.9 mm gap for the USA and Canadian versions.

The FWAL/FWALC supplement lists 63 Nm (45 ft-lb) for the final gear case-to-rear axle housing connection, separately from the other final-drive fasteners.