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1999 Yamaha Grizzly 600 Service Repair Manual 99

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$16.99
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🏷️ Basic Information Identification Make: Yamaha Model: Grizzly 600 Year: 1999 Vehicle Type: ATV (All-Terrain Vehicle) Codes Chassis Code: YFM600FN 👋 Introduction Market Position Segment: High-performance utility ATV segment, positioned...
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类型: Atv
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斯库: 37211
1999 Yamaha Grizzly 600 Service Repair Manual 991999 Yamaha Grizzly 600 Service Repair Manual 991999 Yamaha Grizzly 600 Service Repair Manual 991999 Yamaha Grizzly 600 Service Repair Manual 99
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Grizzly 600
Year:
1999
Vehicle Type:
ATV (All-Terrain Vehicle)
Codes
Chassis Code:
YFM600FN
👋 Introduction
Market Position
Segment:
High-performance utility ATV segment, positioned for serious off-road use and trail riding.
Competitive Analysis
Competitors:
Competed against models like the Honda Foreman 450, Kawasaki Bayou 400, and Suzuki Vinson 500 in its class.
Key Features
Engine Size:
Powerful 600cc engine for its era, offering strong torque for hauling and climbing.
Transmission:
Automatic transmission with a reliable Ultramatic CVT system providing smooth power delivery.
Drivetrain:
On-command 4WD system allowing for rider selection between 2WD and 4WD.
Suspension:
Independent front suspension and a swingarm rear suspension providing good ground clearance and ride comfort.
📋 Manual Details
Coverage Areas
General Information:
Included
Maintenance:
Included
Engine Removal Installation:
Included
Engine Fuel System:
Included
Engine Lubrication Cooling:
Included
Engine Combustion System:
Included
Transmission System:
Included
Front Wheel Steering:
Included
Rear Wheel System:
Included
Fenders Exhaust:
Included
Electrical System:
Included
Troubleshooting:
Included
Page Count
Total Pages:
350+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive diagnosis, repair, and overhaul of the 600cc engine, including cylinder head, piston, crankshaft, camshaft, valve timing, and seals.
Fuel System:
Carburetor tuning and rebuilding (Mikuni BS34), fuel pump, fuel filter, and fuel lines.
Lubrication Cooling:
Oil pump, oil filter, oil passages, cooling system (radiator, fan, coolant), and oil viscosity recommendations.
Combustion System:
Ignition system (CDI, spark plug specifications, timing), compression testing, and cylinder head gasket replacement.
Transmission:
Operation and service of the automatic transmission, including CVT belt inspection and replacement, centrifugal clutch, and drive/driven pulleys.
Drivetrain:
Front and rear differential service, driveshafts, CV joints, and wheel hub bearings.
Suspension:
Front and rear suspension systems, including shocks, springs, A-arms, bushings, and alignment procedures.
Steering:
Handlebar assembly, steering shaft, tie rods, ball joints, and steering stop adjustment.
Brakes:
Front and rear hydraulic brake systems, including master cylinders, calipers, brake pads, brake fluid specifications (DOT 3), and bleeding procedures.
Electrical:
Wiring diagrams, battery specifications, charging system (stator, rectifier/regulator), lighting, starter motor, and switches.
Bodywork Chassis:
Frame inspection, plastic body panel removal and installation, fenders, seat, and handlebars.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug checks, lubrication points, and general upkeep.
Diagnostics:
Systematic troubleshooting guides for common and uncommon issues, error code interpretation (if applicable), and symptom-based diagnostic trees.
Repair:
Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components and systems.
Rebuilds:
Detailed procedures for engine and transmission overhauls, including torque specifications and critical clearances.
Adjustments:
Carburetor synchronization, valve lash adjustment, brake adjustments, and steering alignment.
Wiring Diagrams:
Full electrical schematics for easy troubleshooting of electrical faults.
Special Tools:
Identification of required special tools and their usage.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Equivalent to dealer-level technical information.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Likely searchable text within PDF, enhancing ease of use.
Print Quality
Quality:
Assumed high quality, typical of factory manuals, with clear diagrams and text.
Binding Type
Binding:
Not applicable (PDF Download)
Paper Type
Paper Type:
Not applicable (PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, air-cooled with fan-assisted oil cooling
Displacement:
595cc (approx.)
Bore X Stroke:
95.0 mm x 80.2 mm (approx.)
Compression Ratio:
9.1:1 (approx.)
Performance
Horsepower:
Estimated 35-40 HP (subject to specific tuning and measurement)
Torque:
Strong low-end and mid-range torque for utility tasks.
Fuel System
Carburetor:
Mikuni BS34, single
Fuel Type:
Unleaded gasoline (87 octane recommended)
Lubrication And Cooling
Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, or SG classification. (Check manual for precise recommendation)
Oil Capacity:
Approx. 2.2 L (2.3 US qt) with filter change. (Refer to manual for exact capacity)
Cooling System:
Fan-assisted oil cooling system
🔧 Transmission
Standard
Type:
Automatic (Ultramatic CVT)
Drive System:
Shaft drive
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R)
Transmission Fluid:
Yamaha's recommended CVT fluid or equivalent. (Consult manual for specific part number and type)
Features
Cvb:
Engine braking via CVT system
📐 Dimensions
Exterior
Length:
Approx. 80.7 inches (2050 mm)
Width:
Approx. 44.7 inches (1135 mm)
Height:
Approx. 43.5 inches (1105 mm)
Wheelbase:
Approx. 50.8 inches (1290 mm)
Weights
Dry Weight:
Approx. 540 lbs (245 kg)
Ground Clearance:
Approx. 10.2 inches (260 mm)
Cargo
Front Rack Capacity:
Approx. 88 lbs (40 kg)
Rear Rack Capacity:
Approx. 176 lbs (80 kg)
Tires
Front Tire Size:
AT25x8-12
Rear Tire Size:
AT25x10-12
Wheels
Bolt Pattern:
4/110 mm
🛡️ Safety Features
Ratings
Atv Safety:
ATV safety is rider dependent. This manual emphasizes safe operation and maintenance.
Active Features
Braking:
Hydraulic disc brakes front and rear, offering strong stopping power.
Lighting:
Dual 30W halogen headlights and a 30W taillight/brake light for visibility.
Passive Features
Frame Design:
Robust steel frame construction.
Rollover Protection:
No specific rollover protection system; rider vigilance and proper safety gear are paramount.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable. Basic LCD display for odometer, trip meter, and indicator lights.
Driver Assistance
Assistance Features:
No advanced driver assistance systems; relies on rider skill and experience.
Connectivity
Connectivity Features:
No connectivity features.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1000 km or 6 months, whichever comes first (or every 20 hours of use).
Air Filter Cleaning:
Every 1000 km or 6 months (more frequently in dusty conditions).
Spark Plug Check:
Every 2000 km or 12 months.
Cv Belt Inspection:
Inspect every 2000 km or 12 months. Replace as needed based on wear.
Brake Fluid Flush:
Every 2 years or as needed.
Fluid Specifications
Engine Oil Spec:
Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, or SG.
Brake Fluid Spec:
SAE J1703 or DOT 3
Coolant Type:
Ethylene glycol based antifreeze coolant (50% mixture with distilled water recommended).
Known Issues
Common Wear Items:
CVT belt wear, suspension bushings, brake pads, and wheel bearings are common wear items on higher-mileage units.
Carburetor Cleaning:
Carburetor can be prone to gumming up if fuel sits for extended periods; regular fuel stabilizer use is recommended.
Cooling System:
Fan operation and radiator integrity are crucial for preventing overheating.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, a long-standing and respected manufacturer of motorcycles, ATVs, and marine products known for innovation and reliability.
Model Evolution
Predecessors:
Evolved from Yamaha's earlier utility ATV models, building on a foundation of proven designs.
Successors:
The Grizzly line continued to evolve, with the Grizzly 660 and later 700 models offering increased power and technology.
Production
Production Years:
The Grizzly 600 was produced from approximately 1998 to 2001, with minor variations across model years.
🏆 Awards & Recognition
Recognitions
Industry Reputation:
The Grizzly 600 was well-regarded for its ruggedness, reliability, and strong performance in its class during its production run.
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