Yamaha EFM600 GRIZZLY Manuals

Manuals and User Guides for Yamaha EFM600 GRIZZLY. We have 1 Yamaha EFM600 GRIZZLY manual available for free PDF download: Service Manual

Yamaha EFM600 GRIZZLY Service Manual (348 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 18.02 MB

Exploded Diagrams
4
Illustrated Symbols
5
Contents
6
General Specifications
7
Maintenance Specifications
8
Lubrication Diagrams
14
Cable Routing
15
Chapter Titles
35
Machine Identification
45
Vehicle Identification Number
45
Model Label
45
Features
46
Transmission of Power
46
Clutch & Engine Brake
46
Explanation of Operation
47
Cooling the V-Belt Chamber
47
Auto-Decompression
48
On Command 4WD
48
Gear Motor Installation Steps
49
Lubrication
49
Rear Shock Absorber
50
Revolution and Speed Limiter
50
Important Information
51
Preparation for Removal
51
Replacement Parts
51
Gaskets, Oil Seals and O-Rings
51
Lock Washers/Plates and Cotter Pins
52
Bearings and Oil Seals
52
Circlips
52
Checking of Connections
53
Special Tools
54
How to Use the Conversion Table
78
General Torque Specifications
78
Lubrication Points and Lubricant Types
79
Periodic Inspections and Adjustments
91
Periodic Maintenance/Lubrication Intervals
91
Seat
93
Front Carrier, Front Bumper and Front Fender
94
Rear Carrier and Rear Fender
95
Fuel Tank
96
Engine
97
Valve Clearance Adjustment
97
Timing Chain Adjustment
100
Idling Speed Adjustment
100
Throttle Lever Free Play Adjustment
101
Speed Limiter Adjustment
103
Spark Plug Inspection
104
Ignition Timing Check
105
Compression Pressure Measurement
106
Engine Oil Level Inspection
107
Oil Temp Warning Light Check
108
Engine Oil Replacement
109
Air Filter Cleaning
110
V-Belt Inspection
112
Chassis
114
Front Brake Adjustment
114
Rear Brake Lever and Pedal Adjustment
114
Front Brake Fluid Level Inspection
116
Front Brake Pad Inspection
117
Rear Brake Shoe Inspection
117
Brake Hose Inspection
118
Air Bleeding (Hydraulic Brake System)
118
Select Lever Control Cable and Shift Rod Adjustment
120
Final Gear Oil Level Inspection
121
Final Gear Replacement
121
Differential Gear Oil Replacement
122
Constant Velocity Joint Dust Boot Inspection
123
Steering System Inspection
123
Toe-In Adjustment
124
Rear Shock Absorber Adjustment
126
Tire Inspection
126
Maximum Load Limit
127
Wheel Inspection
128
Cable Inspection and Lubrication
129
Levers, Pedal, Etc. Lubrication
129
Electrical
130
Battery Inspection
130
Charging Method
130
Charging Method Using a Variable-Current (Voltage) Type Charger
133
Charging Method Using a Constant-Voltage Type Charger
134
Fuse Inspection
135
Headlight Beam Adjustment
137
Headlight Bulb Replacement
137
Engine Removal
139
Air Ducts, Muffler, Exhaust Pipe, and Footrest Board (Right)
139
Select Lever Unit and Footrest Board (Left)
140
Hoses and Leads
141
Engine Mounting Bolts
142
Cylinder Head Cover
144
Cylinder Head Cover Removal
145
Cylinder Head Cover Inspection
145
Tappet Cover Inspection
145
Cylinder Head Cover Installation
146
Rocker Arms
147
Rocker Arm Removal
148
Rocker Arm and Camshaft Inspection
148
Rocker Arm Installation
149
Camshaft and Cylinder Head
150
Camshaft and Cylinder Head Removal
152
Camshaft Inspection
153
Camshaft Sprocket Inspection
153
Decompression System Inspection
153
Timing Chain Guide Inspection
154
Timing Chain Tensioner Inspection
154
Cylinder Head Inspection
154
Camshaft and Cylinder Head Installation
155
Valve and Valve Springs
158
Valve and Valve Spring Removal
159
Valve and Valve Spring Inspection
159
Valve and Valve Spring Installation
164
Cylinder and Piston
165
Piston Removal
166
Cylinder and Piston Inspection
166
Piston Ring Inspection
168
Piston Pin Inspection
169
Piston Installation
169
Cylinder Installation
170
Recoil Starter and CDI Magneto
171
CDI Magneto Removal
174
Recoil Starter Disassembly
174
CDI Magneto Inspection
175
Starter Pulley Inspection
175
Recoil Starter Inspection
175
Recoil Starter Assembly
176
CDI Magneto Installation
177
Primary and Secondary Sheaves
179
Primary Sheave
181
Secondary Sheave
182
Primary and Secondary Sheaves Removal
183
Secondary Sheave Disassembly
183
Primary Sheave Inspection
184
Secondary Sheave Inspection
184
Primary Sheave Assembly
185
Secondary Sheave Assembly
185
Primary and Secondary Sheaves Installation
187
Clutch
188
Clutch Removal
190
Clutch Inspection
190
Clutch Installation
191
Crankcase
193
Starter Motor, Timing Chain and Oil Filter
193
Crankcase Bearings
196
Crankcase Separation
197
Timing Chain and Guide Inspection
197
Oil Strainer, Oil Filter and Oil Delivery Pipe Inspection
198
Crankcase Inspection
198
Bearings and Oil Seals Inspection
198
Crankcase Assembly
199
Transmission and Crankshaft
200
Crankshaft Removal
201
Shift Fork Inspection
201
Shift Cam Inspection
202
Transmission Inspection
202
Crankshaft Inspection
203
Crankshaft and Balancer Installation
204
Transmission Installation
204
Oil Pump
206
Oil Pump Inspection
209
Middle Gear
210
Middle Drive Shaft
210
Middle Driven Shaft
211
Middle Drive Shaft Removal
213
Middle Driven Shaft Removal
213
Middle Drive and Driven Gear Shim Selection
216
Middle Drive Shaft Installation
220
Gear Lash Measurement
221
Carburetor
222
Carburetor Disassembly
225
Carburetor Inspection
225
Carburetor Assembly
227
Fuel Level Adjustment
228
Drive Train
230
Troubleshooting
230
Oil Leakage Inspection Steps
231
Constant Velocity Joints and Differential Gear
233
Universal Joint Disassembly
238
Differential Gear Disassembly
238
Universal Joint Removal Steps
238
Constant Velocity Joint Inspection
239
Differential Gear Inspection
239
Constant Velocity Joint Assembly
240
Differential Gear Assembly
241
Universal Joint Installation
241
Differential Gear Lash Measurement and Adjustment
242
Differential Gear Operation Check
244
Rear Axle/Final Drive Gear and Drive Shaft
245
Rear Axle Removal
248
Final Drive Gear Disassembly
248
Final Drive Roller Bearing Removal and Reassembly
249
Final Drive Pinion Gear and Ring Gear Positioning
250
Rear Axle Inspection
254
Drive Shaft Inspection
255
Final Drive Gear Inspection
255
Final Gear Lash Measurement and Adjustment
256
Final Drive Gear Assembly
258
Rear Axle Installation
258
Front Wheels
260
Rear Wheels
261
Wheel Hub Inspection
262
Brake Drum Inspection
262
Brake Disk Inspection
263
Wheel Hub/Brake Drum Installation
263
Wheel Installation
263
Front Brake
265
Brake Pads
265
Brake Pad Replacement
266
Master Cylinder
268
Master Cylinder Inspection
270
Master Cylinder Assembly
270
Master Cylinder Installation
271
Brake Caliper
273
Caliper Disassembly
275
Caliper Inspection
275
Caliper Assembly
276
Caliper Installation
276
Rear Brake
278
Brake Shoe Plate Inspection
280
Brake Shoe Inspection
280
Rear Brake Assembly
281
Rear Brake Installation
282
Steering System
283
Handlebar
283
Handlebar Inspection
285
Handlebar Installation
285
Rear Brake Lever Installation
285
Master Cylinder Assembly Installation
285
Steering Stem
286
Bearing Retainer Removal
288
Steering Stem Inspection
288
Bearing, Retainer Installation
288
Cable Guide Installation
288
Tie-Rod and Steering Knuckle
289
Steering Knuckle Removal
290
Tie-Rod Inspection
290
Steering Knuckle Inspection
290
Ball Joint Inspection
291
Tie-Rod Installation
291
Front Arm and Front Shock Absorber
292
Front Arm Removal
293
Front Arm Inspection
293
Front Shock Absorber Inspection
293
Front Arm Installation
294
Rear Shock Absorber and Swingarm
295
Swingarm Removal
297
Rear Shock Absorber Inspection
297
Swingarm Inspection
298
Rubber Boot Inspection
298
Rubber Boot Installation
298
Swingarm Installation
299
Electrical Components
300
Switch Inspection
301
Inspecting a Switch Shown in the Manual
301
Switch Continuity Inspection
302
Ignition System Circuit Diagram
304
Ignition System Troubleshooting
305
If the Ignition System Fails to Operate (no Spark or Intermittent Spark)
305
Electric Starting System Circuit Diagram
309
Starting Circuit Operation
310
Electric Starting System Troubleshooting
311
If the Starter Motor Fails to Operate
311
Starter Motor
315
Starter Motor Inspection
316
Starter Motor Assembly
317
Charging System Circuit Diagram
318
Charging System Troubleshooting
319
If the Battery Is Not Charged
319
Lighting System Troubleshooting
321
If the Headlight, Tail Light And/Or Meter Light Fail to Come on
321
Lighting System Check
323
Signal System Circuit Diagram
325
Signal System Troubleshooting
326
If the Indicator Light Fail to Come on
326
Signal System Check
328
Cooling System Circuit Diagram
333
Cooling System Troubleshooting
334
If the Fan Motor Does Not Move
334
2WD/4WD Selecting System Circuit Diagram
338
2WD/4WD Selecting System Troubleshooting
339
If the 4WD Indicator Light Fail to Come on
339
Starting Failure/Hard Starting
341
Pool Idle Speed Performance
342
Poor Medium and High Speed Performance
342
Faulty Drive Train
343
Faulty Gear Shifting
344
Faulty Clutch Performance
344
Overheating
345
Faulty Brake
345
Shock Absorber Malfunction
346
Unstable Handling
346
Headlight Dark
346
Bulb Burnt out
346

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Yamaha EFM600 GRIZZLY Manuals

Yamaha EFM600 GRIZZLY Service Manual (348 pages)

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