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stuck in 4 wheel drive

This is a discussion on stuck in 4 wheel drive within the Grizzly Engine & Transmission forums, part of the Grizzly Forums category; Hey guys, Im a newbie here and have a issue w/ my 2003 grizzly 660. During my ride last weekend I noticed that the servo ...


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#1
06-26-2012, 09:45 PM
stuck in 4 wheel drive

Hey guys, Im a newbie here and have a issue w/ my 2003 grizzly 660. During my ride last weekend I noticed that the servo motor for the 4 wheel drive "sounds" like its working but the unit will not come out of 4 wheel.
Could the mechanism be broke in the diff.? The Diff lock works fine.
Any help would be great.
The pic below is what I do on the weekends when Im not riding the 4 wheelers
Thanks
Rot.
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06-26-2012, 11:48 PM
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HAVE A LOOK AT THIS SHOULD HELP YA OR DO A THREAD SEARCH FOR" SERVO MOTOR"


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#1
06-14-2012, 08:18 PM Cheap alternative to replacing 4wd servo in your 08-11 Grizzly 700
I found a way to replace the servo motor only on the newer 700's. Some of you may remember my older post about replacing them in the 02-08 660's.

While I can still can get those motors as well. I finally got the newer servo motors back from the machine shop.

The newer ones fit the following models

07-11 Grizzly 700
08-11 Grizzly 450
09-11 Grizzly 550
08-11 Rhino 700
07-11 Big Bear 400

I just did an install on one yesterday and I took pics and wrote a how to.

This install was on a 08 Grizzly 700 but they should all be the same for the most part.

If you have a skid plate it would be easier to remove it to access the bottom bolt on the servo and also to let the oil drain. I also recommend having the bike in 2wd to ease in installing the servo back on the diff.


Hereís what it looks like in the bike.
This image has been resized. Click this bar to view the full image. The original image is sized 800x600 and weights 140KB.


Hereís what it looks like when the servo assembly is removed.
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This image has been resized. Click this bar to view the full image. The original image is sized 800x600 and weights 172KB.



Remove the 3 10 mm bolts that hold the servo on the diff. Gear oil is going to pour out unless you drain it first.


Remove the six phillips head screws that hold the servo assembly together and it will look like this.
This image has been resized. Click this bar to view the full image. The original image is sized 800x600 and weights 136KB.


Take care not to turn the big black plastic gear. This will cause you problems and will be a headache trying to get everything back in time.

Once apart youíll see the motor and the two small phillips screws holding it in. Donít worry about moving the small white worm gear next to the motor to get the motor out. That wonít be a problem, just donít turn anything on the other half of the case. Once the two screws are removed, carefully pry up on the motor to remove it.
This image has been resized. Click this bar to view the full image. The original image is sized 800x600 and weights 119KB.


Motor once removed. Old motor on left, new motor on right.
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Put the new motor in and reinstall the holdown bracket with the two small phillips screws.
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Put the two halveís back together again making sure not to turn the black plastic gear. Reinstall on your bike, fill with gear oil and enjoy the money you saved vs buying a new servo.
If anyone has any questions or needs a motor please donít hesitate to shoot me pm. Hope this helps.
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#3
06-27-2012, 07:27 AM
before you pull the servo off the diff... check the plugs on the servo to make sure they are seated...then..

just for grins swap the 2 black relays under the seat..one puts it in 4wd the other puts it back into 2wd...(the big white one is diff lock)

let us know..thanks
walt
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#4
07-10-2012, 04:58 PM
The 4 wheel/diff lock works great now.No troubles after getting hit by a car the other nite. I replaced the front upper A arm and now it shifts in and out of 4 wheel nicely.
Thanks for the help guys
Rot.
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