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1999 Yamaha Grizzly 600 Service Repair Manual 99 PDF Download
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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 for serious...
Type: Powersports
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Sku: 37211
Tags:
ATV
Grizzly Models
Yamaha
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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 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: | |
| 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. |