Positioning:
The Yamaha YFM600FWAK (Grizzly 600) was a flagship utility ATV for Yamaha in its segment, known for its robust performance and four-wheel drive capability, aimed at serious off-road enthusiasts, hunters, and agricultural users.
Competitors:
Competed directly with models like the Honda FourTrax Foreman, Suzuki King Quad, and Kawasaki Prairie from the same era, offering similar displacement and feature sets.
Features:
Dominant 4WD system, powerful 600cc engine, independent front suspension (IFS), and robust build quality.
Value Proposition:
This comprehensive factory service manual is indispensable for owners and technicians to maintain, diagnose, and repair the Yamaha YFM600FWAK, ensuring optimal performance and longevity.
Engine Mechanical:
Complete engine overhaul, disassembly, assembly, inspection, and repair of all internal components (pistons, rings, cylinders, crankshaft, camshaft, valves, timing).
Fuel System:
Carburetor inspection, cleaning, adjustment, and rebuilding; fuel pump operation; fuel tank and lines.
Ignition System:
CDI unit, ignition coil, spark plug inspection and testing, stator and pickup coil testing.
Lubrication System:
Oil pump operation, oil filter replacement, oil circuit inspection.
Cooling System:
Radiator inspection, fan operation, thermostat testing, coolant specifications and flushing.
Transmission Drivetrain:
Automatic transmission (CVT) inspection, adjustment, and repair; final drive assembly; driveshaft and differential.
Suspension:
Front and rear suspension component inspection, adjustment, and replacement; shock absorbers; springs; A-arms.
Brakes:
Brake system inspection, hydraulic fluid specifications, brake pad replacement, caliper service, disc inspection, bleeding procedures.
Steering:
Steering system inspection, tie rod ends, steering linkage, lubrication.
Electrical System:
Wiring diagrams, battery testing and replacement, lighting system, starter motor, charging system (alternator/stator), fuses, relays.
Body Chassis:
Frame inspection, body panel removal and installation, fenders, rack removal and installation.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, and drivetrain malfunctions.
Repair Procedures:
Step-by-step instructions for component disassembly, reassembly, and repair for all major systems.
Technical Specifications:
Detailed torque specifications, clearances, tolerances, and alignment procedures.
Wiring Diagrams:
Comprehensive electrical system wiring schematics for accurate diagnostics and repairs.
Rebuild Instructions:
Detailed guidance for engine and transmission rebuilds.
Depth:
Comprehensive Factory Level - Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and specifications.
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
595 cc (36.3 cu. in.)
Bore X Stroke:
95.0 mm x 83.9 mm (3.74 in. x 3.30 in.)
Valve Configuration:
SOHC, 2 valves per cylinder
Horsepower:
Approx. 35-40 HP (estimated, actual may vary)
Torque:
Not specified, but robust for its class
Fuel Delivery:
Mikuni BSR42 carburetor
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Oil Type:
Yamalube 4-stroke engine oil or equivalent SAE 10W-40, API SG or higher
Spark Plug Type:
NGK CR7E or equivalent
Cooling Method:
Forced air cooling with oil cooler
Length:
Approx. 81.7 in. (2075 mm)
Width:
Approx. 43.3 in. (1100 mm)
Height:
Approx. 43.9 in. (1115 mm)
Dry Weight:
Approx. 562 lbs (255 kg)
Ground Clearance:
Approx. 10.4 in. (264 mm)
Front Rack Capacity:
Not specified, but substantial
Rear Rack Capacity:
Not specified, but substantial
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months.
Air Filter Cleaning:
Every 100 km (60 miles) or if operated in dusty conditions.
Spark Plug Check:
Every 1,000 km (600 miles).
Valve Clearance Check:
Every 4,000 km (2,500 miles) or annually.
Engine Oil Capacity:
3.70 L (3.92 US qt) without filter change, 3.90 L (4.12 US qt) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Permanent type antifreeze coolant, 50/50 mix with distilled water.
Common Problems:
Potential for carburetor gumming if fuel sits, CVT belt wear over time, front differential seal leaks on some units, and occasional overheating under heavy load (addressed by better airflow/fan mods).
Troubleshooting Tips:
Regular cleaning of the air filter and carburetor jets is crucial. Ensure proper battery voltage for reliable starting and ignition.
Spark Plug Torque:
18 Nm (13.3 lb-ft)
Oil Drain Plug Torque:
25 Nm (18.4 lb-ft)
Heritage:
Yamaha has a long and storied history in powersports, known for innovation and reliability, particularly in motorcycles and ATVs.
Evolution:
The YFM600FWAK was part of Yamaha's significant expansion into the utility ATV market, building on the success of earlier models. It represented a step up in power and capability, culminating in the later Grizzly 660 and 700 models.
Production Years:
1998-2001 for this specific YFM600FWAK variant.
Manufacturing Location:
Primarily manufactured in Japan by Yamaha Motor Corporation.
