Welcome to the factory service repair manual for the Grizzly 600, covering model years 1998 through 2001. This powerful 4-stroke, liquid-cooled ATV, powered by a 595 cc engine and featuring automatic CVT transmission, is renowned for its robust off-road capability and reliability. Designed for demanding terrain, the Grizzly 600 offers selectable 2WD/4WD, substantial towing capacity, and practical rack load capacities, making it a versatile machine for work and recreation. Its engineering prioritizes durability and performance, solidifying the brand's reputation in the powersports industry.
This comprehensive manual provides in-depth technical information for all aspects of the Grizzly 600. It includes detailed explanations of systems such as the fuel, cooling, engine lubrication, clutch, and electrical systems, along with procedures for engine removal and installation, crankshaft and transmission, brakes, suspension, steering, and frame. You will find step-by-step repair procedures, diagnostic guidance for common issues, preventative maintenance schedules, and essential technical specifications. This resource is designed to empower owners and technicians with the knowledge needed to maintain, troubleshoot, and repair the vehicle effectively, ensuring optimal performance and longevity.
Model Years Covered:
1998, 1999, 2000, 2001
Positioning:
Comprehensive DIY and professional repair resource for the Yamaha Grizzly 600, enabling significant cost savings on labor.
Competitiveness:
Provides genuine factory information, often surpassing third-party manuals in accuracy and completeness, offering a direct alternative to costly dealership services.
Unique Selling Points:
Genuine factory content, detailed troubleshooting, printable format, direct download for immediate access, significant cost savings.
Estimated Page Count:
Hundreds
Type:
Factory Service Repair Manual
General Information:
Included
Engine Lubrication System:
Included
Engine Removal Installation:
Included
Crankshaft Transmission:
Included
Electrical System:
Included
Diagnostics:
Engine fault symptoms, advanced troubleshooting guide
Repair Procedures:
Step-by-step guidance for all maintenance and repair tasks
Maintenance:
Fundamentals of maintaining and repairing
Testing Suspected Parts:
Secret techniques used by top mechanics
Wiring Diagrams:
Tracing and verifying
Engine Management Systems:
Understanding and analysis
Common Fixes:
Guidance for owners to communicate with mechanics
Mechanic Evaluation:
Tips on checking mechanics and what to ask
Preventative Maintenance:
Tips before small problems escalate
Depth:
Complete official factory information, detailing every aspect for repair, maintenance, rebuilding, refurbishing, and restoration.
Printability:
Printable without any restriction, individual pages or entire manual
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download)
Text Search:
Enabled via PDF reader
Illustrations:
Detailed illustrations, drawings, and photos
Instructions:
Numbered instructions, detailed substeps, notes, cautions, warnings, bold figure numbers
Software Requirement:
Adobe PDF Reader
Type:
4-stroke, SOHC, 4-valve
Cooling System:
Liquid-cooled
Horsepower Estimate:
Approximately 40-45 HP (estimated, actual may vary slightly by year/tuning)
Torque Estimate:
Approximately 33-36 lb-ft (estimated, actual may vary slightly by year/tuning)
Carburetor:
Mikuni BSR34 (single)
Fuel Type:
Unleaded gasoline
Ignition:
CDI (Capacitor Discharge Ignition)
Type:
Automatic Continuously Variable Transmission (CVT) with Ultramatic system
Optional Transmission:
N/A
Drive Modes:
2WD/4WD selectable, shaft drive
Gear Reduction:
High and Low range, Neutral, Reverse
Transmission Fluid:
Yamalube SAE 10W-30 or equivalent (specific grades detailed in manual)
Length:
Approx. 81.7 in (2075 mm)
Width:
Approx. 44.7 in (1135 mm)
Height:
Approx. 45.9 in (1165 mm)
Dry Weight:
Approx. 595 lbs (270 kg)
Fuel Capacity:
Approx. 4.8 gal (18 L)
Towing Capacity:
Approx. 1521 lbs (690 kg)
Rack Load Capacity Front:
Approx. 88 lbs (40 kg)
Rack Load Capacity Rear:
Approx. 176 lbs (80 kg)
Safety Features Overview:
Designed for off-road use; emphasis on stability and rider control.
Braking System:
Hydraulic disc brakes (front and rear)
Parking Brake:
Lever type, caliper mounted
Lighting:
Dual headlights, taillight/brake light
Seatbelt:
N/A (ATV operation)
Infotainment System:
N/A (Utility ATV, focus on function over features)
Driver Assistance Features:
N/A
Connectivity Options:
N/A
Dashboard:
Digital display with speedometer, odometer, trip meter, fuel gauge, clock, 2WD/4WD indicator, neutral indicator, reverse indicator.
Oil Change Interval:
Refer to manual (typically every 1000-2000 miles or annually)
Air Filter Cleaning:
Refer to manual (frequent checks recommended in dusty conditions)
Spark Plug Replacement:
Refer to manual (typical range 3000-6000 miles)
Engine Oil:
Yamalube 4-Stroke SAE 10W-40 API SG or higher (check manual for precise spec)
Engine Oil Capacity:
Approx. 1.8 L (1.9 US qt) with filter change
Coolant:
Yamaha Super Coolant or equivalent permanent type antifreeze (50/50 mix with distilled water)
Common Wear Items:
CVT belt wear, carburetor jetting issues (depending on altitude/usage), potential stator failures, front differential wear with aggressive use.
Maintenance Tips:
Regularly clean air filter, check CVT belt condition, ensure proper coolant levels, keep electrical connections clean.
Yamaha Heritage:
Yamaha Motor Company is a globally recognized leader in powersports, known for innovation, quality, and performance across motorcycles, ATVs, and marine products.
Grizzly Evolution Context:
The Grizzly 600 was a significant model for Yamaha in the rapidly growing utility ATV market, known for its robust design and off-road capability. It laid the groundwork for future Grizzly generations.
Manufacturing Origin:
Japan (typical for Yamaha powersports of this era)
Industry Recognition:
While specific awards for this model year are not readily documented, the Grizzly line is generally recognized for its off-road prowess and reliability, contributing to Yamaha's strong reputation in the ATV market.
