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

Yamaha directs readers to use the service supplements with the base manual; all three service publications are included. The owner's manual supports operating knowledge, preventive maintenance, and minor repair work.

Service coverage: The factory service chapters apply to the K and L variants identified above. The YFM600FWAN(C) publication is the owner's manual.

PDF Search, Bookmarks, and Diagram Detail

Search and navigation: Both PDFs include searchable OCR text and embedded bookmarks, although OCR errors affect some words and some owner's-manual bookmarks miss the section opening. Small circuit-diagram labels require zooming; labels in dark, patterned areas remain difficult to read.

The ZIP contains two printable PDFs totaling 509 pages. The 348-page service file combines the three service publications and one additional set-cover page; the owner's manual is a separate PDF. Page counts include all covers and blank pages, plus three nontechnical additional pages in the owner's manual and one in the base service manual.

Engine, Shaft-Drive, and Electrical Service

The following selected coverage highlights are not a complete contents list. Other topics include spark-arrester cleaning and headlight beam adjustment.

• Engine repair: Engine removal, cylinder-head and rocker-arm service, camshaft and timing-system work, valve and valve-spring inspection, piston and cylinder service, crankcase separation, and crankshaft/balancer installation.

• CVT and internal drive: Primary and secondary sheave service, centrifugal clutch inspection, V-belt checks, transmission and shift-component inspection, oil-pump service, and middle-gear setup.

• Front and rear driveline: Universal and constant-velocity joint service, differential disassembly and assembly, on-command 2WD/4WD gear-motor operation, rear-axle removal, final-drive gear positioning, and gear-lash adjustment.

• Brakes, steering, and suspension: Front master-cylinder and caliper service, hydraulic bleeding, rear drum-brake repair, wheel and hub inspection, steering-stem and tie-rod work, toe-in adjustment, front-arm service, and swingarm and shock inspection.

• Carburetor service: Mikuni BST40 removal and disassembly, needle-valve and diaphragm inspection, reassembly, float-height measurement, and fuel-level adjustment.

• Electrical fault finding: Switch and connector checks, ignition and charging tests, starter-motor inspection, lighting and indicator diagnosis, cooling-fan testing, and 2WD/4WD fault tracing.

• Owner operation and maintenance: Pre-operation checks, control use, cold and warm starting, high/low/reverse selection, break-in, cargo and towing guidance, terrain techniques, and periodic service schedules.

Yamaha prepared the service material primarily for dealers and qualified mechanics with mechanical repair knowledge; the owner's manual provides a separate level of guidance for routine upkeep and minor repairs.

Engine Repair and Workshop Preparation

The base service manual uses exploded assembly views, numbered job charts, and step-by-step instructions for work such as camshaft installation and crankcase assembly. Component-specific torque tables, wear limits, clearances, fluid capacities, and adjustment data support inspection and reassembly decisions.

The engine sections cover wet-sump lubrication and the oil-cooler circuit, along with electric and recoil starting. Lubrication diagrams and cable-routing drawings support component identification and installation.

Special tools: The list identifies the crankcase separating tool 90890-01135 / YU-01135-A and sheave spring compressor 90890-04134 / YM-04134, helping you check workshop requirements before disassembly.

Gear-lash measurement tool 90890-01231 / YM-01231 and pocket tester 90890-03112 / YU-03112 support drivetrain measurements and electrical checks. Valve, crankshaft, clutch, bearing-retainer, and universal-joint tools are also identified.

Driveline Setup and Repair Cautions

Middle-gear shim selection uses markings on the crankcase, bearing housing, and gears. The shaft-drive troubleshooting chart connects symptoms such as rumbling, whining, or jerky movement with checks for bearing damage, incorrect gear lash, and damaged gear teeth.

Pressing directly on the middle driven shaft end can damage its threads, while insufficient shaft-drive gear lash can damage the gear teeth. The manual also identifies left-hand threads on the middle driven shaft bearing retainers and final-drive bearing retainer.

Electrical Tests and Circuit Diagrams

System-specific circuit diagrams cover ignition, electric starting, charging, cooling-fan control, and 2WD/4WD selection. A separate full-vehicle wiring sheet is not included.

The starting-circuit explanation shows how the neutral switch, rear brake switch, and cut-off relay affect starter operation. Paired with switch, relay, and motor tests, it supports tracing a no-crank complaint before treating it as a starter-motor failure.

Model-Specific Supplements

The California supplement updates the model code and carburetor specifications. The L/LC supplement identifies regional 5GT1 through 5GT5 configurations and updates engine, chassis, and electrical specifications, oil-cooler lubrication diagrams, and cable routing.

Controls, Maintenance, and Riding

The owner's manual explains vehicle and model identification, on-command 2WD/4WD controls and indicator behavior, the oil-temperature warning-light decision chart, speed-limiter adjustment, accessory-connector limits, and drive-selector operation.

Its pre-ride checklist covers brakes, fuel, engine oil, final and differential oils, throttle action, axle boots, tires, lights, and fasteners. Riding chapters address loading and trailer limits, cold-weather operation, hill climbing and descending, slope crossing, shallow water, rough terrain, and sliding. Cleaning, storage, and basic troubleshooting are also covered.

Brake, driveline, and internal-engine repair require the stated tools and mechanical knowledge; Yamaha warns that repair attempts without that foundation can leave the ATV unsafe or unfit for use.

Preview: Cold Valve Clearances and Middle-Gear Lash

Valve adjustment: The YFM600FWAK service manual specifies cold clearances of 0.05–0.10 mm for the intake valves and 0.12–0.17 mm for the exhaust valves. These values accompany the valve-clearance inspection and adjustment procedure.

Middle-gear setup: The same base manual specifies 0.1–0.3 mm of middle-gear lash, with measurement instructions and shim-selection information for this assembly. This is a middle-gear specification, not the differential or final-drive setting.