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post #1 of 24 Old 07-08-2019, 03:41 PM Thread Starter
 
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2002 yamaha 660 grizzly camo

Thanks for letting me join the team, I'm a somewhat newbie to the grizzly, and do all my own maintenance, but I've done a lot of work on my grizzly and still having trouble, the 4x4 light comes on and cuts out at half throttle, I've rebuilt the carbrator, new spark plug, new air filter and new petcock, fuel line, and cleaned out the gas tank, and it still does the same thing, half throttle cutout, please help me... Thanks y'all
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post #2 of 24 Old 07-08-2019, 10:14 PM
 
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Originally Posted by Chigg79 View Post
Thanks for letting me join the team, I'm a somewhat newbie to the grizzly, and do all my own maintenance, but I've done a lot of work on my grizzly and still having trouble, the 4x4 light comes on and cuts out at half throttle, I've rebuilt the carbrator, new spark plug, new air filter and new petcock, fuel line, and cleaned out the gas tank, and it still does the same thing, half throttle cutout, please help me... Thanks y'all
Welcome aboard. Is the diff lock light on too?

Does it stop cutting out at half throttle if you push the diff lock override button? Stop throwing money at the motor until you verify it is not the diff-lock cutout doing it.

Here's a great resource for 4wd troubleshooting: Troubleshooting ? 501 Parts.com Yamaha 4wd System Parts and Repair right, @oleblue22 ?

2011 Grizzly 450 EPS
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on Rock A168 rims
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rear brake lever run in vertical orientation
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post #3 of 24 Old 07-09-2019, 09:10 AM Thread Starter
 
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Thanks for the help, but the diff lock light comes on after I've reached the half throttle cut out point and once it hesitates a couple times, but I'm going to replace the cdi box and go from there, I don't know how/where the diff lock override button is?
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post #4 of 24 Old 07-09-2019, 10:34 AM
 
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Originally Posted by Chigg79 View Post
Thanks for the help, but the diff lock light comes on after I've reached the half throttle cut out point and once it hesitates a couple times, but I'm going to replace the cdi box and go from there, I don't know how/where the diff lock override button is?
Here:


If your 4wd is still acting up, I highly recommend not replacing CDI or anything else motor related until you get the 4wd working exactly like it should be. You can have a 100% perfectly working motor and electrical system for the motor, but if 4wd isn't working right it is designed to cut out your motor with the exact symptoms you described.

2011 Grizzly 450 EPS
Artrax CTX 26-9-12's all around
on Rock A168 rims
JBS sheave - no shim
18 gram Dr Pulley overdrive sliders
MotionPro twist throttle kit
rear brake lever run in vertical orientation
gripper seat cover
rear fender flares
Champion 3000 lb winch w/ synthetic rope
KFI 48" plow + wings
handlebar mounted light bar
homemade electric plow angle
homemade plow lifted height indicator

2004 Rancher AT
+ Lots of other Honda's in the family
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post #5 of 24 Old 07-09-2019, 07:33 PM Thread Starter
 
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Is it the Grey electronic start button?
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post #6 of 24 Old 07-09-2019, 07:36 PM Thread Starter
 
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So do I need to push the grey button while driving it? Or what, I greatly appreciate your help with this....
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post #7 of 24 Old 07-09-2019, 08:16 PM
 
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Quote:
Originally Posted by Chigg79 View Post
Is it the Grey electronic start button?
Wow, no it's definitely not the electric start button. I had thought all years of the 660 had the override button, but it is not there on your 2002. I searched partzilla and sure enough your 2002 shares the same switch as other models that don't have diff-lock. The 2006 660's had it. So maybe someone else with a 2002 will chime in.

2011 Grizzly 450 EPS
Artrax CTX 26-9-12's all around
on Rock A168 rims
JBS sheave - no shim
18 gram Dr Pulley overdrive sliders
MotionPro twist throttle kit
rear brake lever run in vertical orientation
gripper seat cover
rear fender flares
Champion 3000 lb winch w/ synthetic rope
KFI 48" plow + wings
handlebar mounted light bar
homemade electric plow angle
homemade plow lifted height indicator

2004 Rancher AT
+ Lots of other Honda's in the family
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post #8 of 24 Old 07-09-2019, 09:16 PM Thread Starter
 
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On the right side of the handlebars is where I put mine in 4x4 and diff lock. So I don't know what to do now, just replace the servo and 4x4 switch?
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post #9 of 24 Old 07-10-2019, 05:08 AM
 
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Wow, no it's definitely not the electric start button. I had thought all years of the 660 had the override button, but it is not there on your 2002. I searched partzilla and sure enough your 2002 shares the same switch as other models that don't have diff-lock. The 2006 660's had it. So maybe someone else with a 2002 will chime in.
2002-2004 Grizzly 660 do "not" have diff-lock override.

2005-2008 Grizzly 660 do have override.

I wish mine had it sometimes. But very rarely.
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post #10 of 24 Old 07-10-2019, 05:10 AM
 
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Originally Posted by Chigg79 View Post
On the right side of the handlebars is where I put mine in 4x4 and diff lock. So I don't know what to do now, just replace the servo and 4x4 switch?
I would first start by removing the front diff actuator electrical connectors and clean them using contact cleaner or brake cleaner. Apply dielectric grease and reconnect.
Sometimes water can enter those connections and give you issues.
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post #11 of 24 Old 07-10-2019, 05:36 AM Thread Starter
 
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Thanks for all the input on this situation y'all, I greatly appreciate y'all, the crazy thing about this is... It ran perfect for weeks of riding and just all at once, started acting up on the way back to the woods, the 4x4 light comes on at half throttle and once it cuts out and hesitate the diff lock light comes on? I'll try cleaning up all the connectors to it and see what happens... Thanks again
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post #12 of 24 Old 07-10-2019, 12:45 PM
 
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Originally Posted by Chigg79 View Post
Thanks for all the input on this situation y'all, I greatly appreciate y'all, the crazy thing about this is... It ran perfect for weeks of riding and just all at once, started acting up on the way back to the woods, the 4x4 light comes on at half throttle and once it cuts out and hesitate the diff lock light comes on? I'll try cleaning up all the connectors to it and see what happens... Thanks again
That is how most electrical problems start.

If cleaning the actuator connectors do not work, then I would inspect wiring harness for chafed wires. Pay particular attention to the wire bundle down by the actuator and the wire bundle at the relays.
Go to www.501parts.com for further details, with pictures.
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post #13 of 24 Old 07-10-2019, 04:04 PM Thread Starter
 
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Okay thanks, I will fully inspect all the wire, hopping I will be able to this weekend, but just by closely looking, seem fine, but I will clean it all up and see what happens... Thanks again
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post #14 of 24 Old 07-10-2019, 04:43 PM
 
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dezz, 2004 660 has “override” button, at least mine does. 🙂




--------------------------
2004 Grizzly 660 4x4
2003 Kodiak 400 4x2
2001 Kodiak 400 4x4
2005 Bruin 350 4x4

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post #15 of 24 Old 07-11-2019, 06:04 AM
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Okay thanks, I will fully inspect all the wire, hopping I will be able to this weekend, but just by closely looking, seem fine, but I will clean it all up and see what happens... Thanks again
What Dezz said was spot on, it sounds like a wire that is shorted or making intermittent contact. I've seen the wires break inside the insulation before so you have to use a multimeter to ohm out the wires. The link in my signature has videos on how to test all the components of the 4wd system. Clean up the two plugs on the servo first and see where that gets you and let us know what you find.

Yamaha ATV/SxS 4wd System Parts and Repair

4wd problems? Start here..

Troubleshooting | 501 Parts ...
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