The Grizzly 600 All-Terrain Vehicle (ATV), produced from 1998 to 2001, is renowned for its robust construction and exceptional 4x4 capabilities. This model, powered by a 595cc liquid-cooled, four-stroke engine, features reliable Ultramatic CVT automatic transmission and the On-Command 2WD/4WD system, allowing for seamless selection of drive modes. Designed for demanding terrain, the Grizzly 600 offers impressive towing capacity and was a benchmark in the utility ATV market, earning industry recognition for its dependable performance and rugged design. This comprehensive service repair manual, written in English, provides detailed guidance for the maintenance and repair of your Grizzly 600 ATV. It covers essential areas including engine systems, drivetrain, chassis components, and the electrical system, with specific procedures for engine rebuilds, transmission repairs, and steering system maintenance. The manual includes preventative maintenance schedules, troubleshooting diagnostics for common issues, and factory-level repair information, making it an indispensable resource for DIY enthusiasts, professional technicians, and all Grizzly 600 owners seeking to ensure their vehicle's optimal performance and longevity. 🏷️ Basic Information Identification Make: Yamaha Model: Grizzly 600 Model Years Covered: 1998, 1999, 2000, 2001 Vehicle Type: All-Terrain Vehicle (ATV) Codes Engine Code Family: 3VR 👋 Introduction Market Position Target Audience: DIY enthusiasts, professional technicians, ATV owners Competitive Analysis Value Proposition: Cost savings through self-repair, factory-level repair information Key Features Illustration Quality: Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: PDF Download Page Count Page Count: 350+ 📖 Manual Coverage Systems Covered Engine Systems: Engine Removal and Installation, Engine Fuel System, Engine Lubrication and Cooling, Engine Combustion System Drivetrain Systems: Transmission System Chassis Systems: Front Wheel and Steering System, Rear Wheel System, Fenders and Exhaust Pipe Electrical Systems: Electrical System Procedures Included Maintenance: General Maintenance Procedures, Preventative Maintenance Repair And Rebuild: Engine Rebuild, Transmission Repair, Steering System Repair, Suspension Repair Troubleshooting: Diagnostic Procedures, Troubleshooting Common Issues Technical Depth Depth: Comprehensive Service and Repair, Factory-Level Diagnostics 📊 Manual Specifications File Format File Type: PDF Compatibility: Windows, Linux, Mac OS Print Quality Printable: Yes Binding Type Delivery Method: Instant Download Paper Type Digital Format: E-Book, zipped/rar (requires unzipping software) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 4-valve, Liquid-cooled Displacement: 595cc Bore X Stroke: 95.0 mm x 80.2 mm Performance Horsepower Estimate: ~35 HP (estimate, varies by tuning and regulations) Torque Estimate: ~45 Nm (estimate, varies by tuning and regulations) Fuel System Carburetor: Mikuni BSR42 (typically twin carburetors for later models) Fuel Type: Unleaded gasoline Lubrication And Cooling Cooling System: Liquid-cooled Oil Type Recommendation: Yamalube 4 (or equivalent SAE 20W-40 API SG or higher) Oil Capacity: Approx. 2.2 L (when replacing filter) 🔧 Transmission Standard Transmission Type: Automatic (Yamaha Ultramatic CVT) Drive System: Shaft Drive (2WD/4WD selectable, On-Command 4WD system) Features Gear Selection: High, Low, Neutral, Reverse Cvt Fluid Type: Yamaha Belt Oil (or equivalent) 📐 Dimensions Exterior Length: Approx. 2,070 mm (81.5 in) Width: Approx. 1,120 mm (44.1 in) Height: Approx. 1,170 mm (46.1 in) Weights Dry Weight: Approx. 255 kg (562 lbs) Curb Weight: Approx. 270 kg (595 lbs) Towing Capacity: Approx. 600 kg (1,322 lbs) Front Tire Size: AT25x8-12 Rear Tire Size: AT25x10-12 🛡️ Safety Features Ratings Atv Safety Considerations: Always wear a helmet and appropriate protective gear; ride within your limits; follow all safety warnings in the manual. 💡 Technology Features Infotainment Instrument Panel: Digital display with speedometer, odometer, trip meter, fuel gauge, 4WD indicator, neutral/reverse indicators, high beam indicator. Driver Assistance 4Wd System: Yamaha's On-Command 2WD/4WD system allowing for on-the-fly selection. Connectivity Lighting: Dual headlights, rear brake light. 🔧 Maintenance Service Intervals Engine Oil Change: Every 1,000 km or 6 months (whichever comes first) Air Filter Cleaning: Every 200 km or 3 months, replace annually Spark Plug Replacement: Every 5,000 km or 2 years Fluid Specifications Engine Oil Specification: Yamalube 4, SAE 20W-40, API SG or higher Brake Fluid Specification: DOT 3 Coolant Specification: Ethylene glycol-based antifreeze (50/50 mix with distilled water) Known Issues Common Wear Items: Brake pads, wheel bearings, CV joint boots, drive belts (CVT) Potential Engine Concerns: Carburetor adjustment/cleaning, occasional starter issues (ensure battery health) Drive System Checks: Regular inspection of driveshafts, U-joints, and differential fluids 📚 Vehicle History Brand Heritage Manufacturer: Yamaha Motor Corporation Model Evolution Series Introduction: The Grizzly line, known for its ruggedness and 4x4 capabilities, was established in the mid-1990s with the introduction of the Grizzly 600, setting a benchmark for utility ATVs. Production Production Period: The Grizzly 600 was produced from the mid-1990s through the early 2000s, with this manual covering the key models from 1998-2001. 🏆 Awards & Recognition Recognitions Industry Standing: The Yamaha Grizzly 600 was widely recognized for its robust construction, reliable performance, and excellent 4x4 capabilities, making it a popular choice in its segment.