Fixing up a 1999 Yamaha Grizzly 600 on a budget

On Apr 26, 2016

In the August 1997 issue, NFL great Brett Favre helped us test out the new Grizzly. Since then, he has quit playing football so he could ride full-time.

Most of our project machines focus on fixing up a cool sport quad or making super-monster 4x4s. This time around we are taking a more subtle approach and fixing up a beat-up, old ranch quad that the owner just wanted to get up and running. The 1999 Yamaha Grizzly 600 4×4 was one step away from being a basket case. It was complete but barely running and in much need of some TLC. We gave it that and more. The before-and-after photos will show the finished product, as well as explain how we made the transformation.

BODYWORK
Okay, we went a little overboard on refurbishing the bodywork on the Griz. However, we wanted to show how well the hydrographics process works. This type of custom coating can be applied to virtually any part of any machine. Hydrodipping is the same process most high-end and special-edition ATVs come with from the factory, and it is strong. Humboldt Hydrographics in Eureka, California, transformed our old, scratched-up, drab-green plastic into a beautiful wheeler ready for the next hunt. Each piece was dipped separately, then bolted back together with stock hardware and new plastic pushpins. Prices to do this to a complete set of your ATV bodywork starts at $499, and there are over 10,000 patterns to choose from. The camo we used is called Evo. Call Humboldt Hydrographics at (707) 444-9545 or log on to www.humboldthydrographics.com and like www.facebook.com/humboldthydrographics.

BUMPER
ATV bumpers can be used for all sorts of chores—from herding cattle to opening farm gates. We tweaked the stock bumper back straight, added a coat of spray paint and called it good. You can buy the small plastic body rivets from the dealer or at your local home-improvement store in the specialty hardware section.

CVT
Amazingly, the stock CVT belt on this decade-and-a-half-old Grizzly was in great shape. However, instead of putting the stocker back on, we went for EPI’s Severe Duty belt. It comes with a one-year warranty, and we expect it to outlive the stocker. While we had the clutch cover removed, we used an air compressor to blow debris out of the CVT system. The EPI belt sells for $135. Call EPI at (218) 829-6036.

SEAT
If you leave an ATV outside for years, the first thing to go is the seat cover. Sun and extreme temperatures eat away at the material. We had the stock seat base re-foamed and covered by Saddlemen. They carry covers for almost every two-, three- and four-wheeler made. Covers in a variety of colors start at $89. Contact Saddlemen at www.saddlemen.com.

TIRES
This machine had thousands of on- and off-road miles and only had one tire change. We found it with a well-worn set of Kenda Bear Claws still holding air. So, not to change things up too much, we wrapped the stock wheels with a brand-new set of Kenda rubber. The owner liked how smooth the Bear Claws are and how long they lasted. At www.kendausa.com you can see the complete line of sport and utility tires or ask your dealer.

BATTERY AND ELECTRICAL
Yamaha batteries are usually the first ones to wear out in our experience, and this Grizzly was no different. We swapped out the stock battery with a lighter-weight $249 Shorai battery that fit right into the stock location. ShoraiPower.com has batteries for every quad you need to replace. We fixed another electrical issue by replacing the entire wiring loom for $85 from Powersports Nation. The stock loom was routed too close to the exhaust pipe and melted through. At PowersportsNation.com you can source and stock parts from any machine you can think of. The website shows photos of the product, and they ship directly to your door. You don’t even have to get your hands dirty looking for it.

PISTON
We had CT Racing give the stock cylinder a quick hone while they had the head off doing a much-needed valve job. CT is an expert in two- and four-stroke top ends, and they made the old Grizzly run like new. A Namura piston helped bring the powerplant back to life by supplying their complete topend kit. The kit includes a piston, rings, gaskets and new O-rings to seal things up. We also used one of their handy carburetor rebuild kits to replace the much-needed jets and seals. In addition, Namura Technologies has a complete catalog of hard parts, including everything from shocks to clutch kits. See the huge parts catalog at www.namura.com. You can contact CT Racing at (562) 945-2453. Their website, www.ctracing.com, has a ton of helpful engine tips, so check it out.