2002 yamaha 660 grizzly - Yamaha Grizzly ATV Forum
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post #1 of 6 Old 07-08-2019, 04:05 PM Thread Starter
 
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2002 yamaha 660 grizzly

4x4 light staying on, motor has half throttle cutout with hesitation, but runs fine lass than half throttle, I drained and cleaned the gas tank, new petcock with new fuel line and done a complete carburetor rebuild, new spark plug, and new air filter...and nothing changed, please help me figure this out... Thanks
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post #2 of 6 Old 09-27-2019, 05:37 PM
 
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Originally Posted by Chigg79 View Post
4x4 light staying on, motor has half throttle cutout with hesitation, but runs fine lass than half throttle, I drained and cleaned the gas tank, new petcock with new fuel line and done a complete carburetor rebuild, new spark plug, and new air filter...and nothing changed, please help me figure this out... Thanks


Hi Chigg79, just wondering if you got this sorted out? If not the problem isnít anything wrong with engine or fueling, itís your 4wd sticking in or the 4wd switch, when you switch the 4wd switch on or off the engine automatically cuts revs to make it easier for 4wd to engage or disengage.
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post #3 of 6 Old 09-27-2019, 06:52 PM
 
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Originally Posted by Chuggy500 View Post
Hi Chigg79, just wondering if you got this sorted out? If not the problem isnít anything wrong with engine or fueling, itís your 4wd sticking in or the 4wd switch, when you switch the 4wd switch on or off the engine automatically cuts revs to make it easier for 4wd to engage or disengage.
The engine does not cut rpm's for engaging or disengaging 4wd. The switch sticking would have no effect on engine rpm.

The ATV has a speed limiter while in diff lock mode. It will cut rpm and spudder the engine once you hit that specific speed. The 2002-2004 Grizzly 660's do not have any ways around this limiter. In 2005, a limiter bypass button was added to the left handlebar stalk, allowing the rider to bypass the limiter for full power and speed in diff lock.


To the OP, I would first start by removing the electrical connectors from the front diff actuator and cleaning them using contact or brake cleaner. Then apply dielectric grease and reinstall. Sometimes moisture gets in those connectors and causes the diff lock limiter to engage without being in duff lock.
I would also take apart the 4wd switch on the handlebar and clean the contacts inside it. This is s very common issue to get dirty and create issues with the 4wd and engine running. Lots of videos on this on YouTube or go to 501parts.com website for several videos with lots of troubleshooting for the Yamaha 4wd system.
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post #4 of 6 Old 09-28-2019, 08:23 PM
 
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Originally Posted by dezz View Post
The engine does not cut rpm's for engaging or disengaging 4wd. The switch sticking would have no effect on engine rpm.



The ATV has a speed limiter while in diff lock mode. It will cut rpm and spudder the engine once you hit that specific speed. The 2002-2004 Grizzly 660's do not have any ways around this limiter. In 2005, a limiter bypass button was added to the left handlebar stalk, allowing the rider to bypass the limiter for full power and speed in diff lock.





To the OP, I would first start by removing the electrical connectors from the front diff actuator and cleaning them using contact or brake cleaner. Then apply dielectric grease and reinstall. Sometimes moisture gets in those connectors and causes the diff lock limiter to engage without being in duff lock.

I would also take apart the 4wd switch on the handlebar and clean the contacts inside it. This is s very common issue to get dirty and create issues with the 4wd and engine running. Lots of videos on this on YouTube or go to 501parts.com website for several videos with lots of troubleshooting for the Yamaha 4wd system.


Hi Dezz, my mistake about the 4wd switch, I actually meant the diff lock but the revs cut issue a different story, I saw this post a week ago and had a fair idea what his problem was but as I donít have a 660 I didnít comment leaving it to those with a 660 to let him know what the problem was however no one bothered to set him in the right direction so I at least passed on my experience to him thinking maybe the 4wd diff lock system was much the same on the 660 as on my 700's and Viking but by the sounds of it they are different regarding the revs cut as the 700's and Viking not only hit the rev limiter @ 30kph but also cut revs to basically idle when engaging the and disengaging the diff lock, it wonít always be noticeable if lock engages / disengages instantly however if it has load on one front wheel then it just keeps coughing and spluttering until lock engages or disengages, however I didnít know that the 660's didnít have that feature so thanks for setting me straight on that.
Cheers
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post #5 of 6 Old 09-29-2019, 12:12 PM
 
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Originally Posted by Chuggy500 View Post
Hi Dezz, my mistake about the 4wd switch, I actually meant the diff lock but the revs cut issue a different story, I saw this post a week ago and had a fair idea what his problem was but as I donít have a 660 I didnít comment leaving it to those with a 660 to let him know what the problem was however no one bothered to set him in the right direction so I at least passed on my experience to him thinking maybe the 4wd diff lock system was much the same on the 660 as on my 700's and Viking but by the sounds of it they are different regarding the revs cut as the 700's and Viking not only hit the rev limiter @ 30kph but also cut revs to basically idle when engaging the and disengaging the diff lock, it wonít always be noticeable if lock engages / disengages instantly however if it has load on one front wheel then it just keeps coughing and spluttering until lock engages or disengages, however I didnít know that the 660's didnít have that feature so thanks for setting me straight on that.
Cheers
Now I understand better. You would be 100% correct.
When the diff lock button is pressed, but the diff lock is bot fully engaged, the light should flash. At this point, engine RPM is very limited.
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post #6 of 6 Old 09-29-2019, 06:23 PM
 
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Now I understand better. You would be 100% correct.

When the diff lock button is pressed, but the diff lock is bot fully engaged, the light should flash. At this point, engine RPM is very limited.


Yeah thatís it, do the 660's do this too? I notice it a lot on my 17 Viking more so than the Grizzlyís, often takes quite a while to disengage spluttering the whole time itís trying
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