A little more info here, i was in a rush yesterday. Everything in the clutch seems fine. In neutral, the belt goes up/down in the primary/secondary.

About two weeks ago, i sunk the grizz. I changed the oil several times, front diff, radiator, and gas tank but somehow i forgot to check the rear diff. I went on a 20 mile ride monday with no issues other than what i think was a cv joint on the left rear. It would pop while turning at low speeds.

Then yesterday it was fine all the way up until the mechanic was driving it up into my trailer and it locked up. He should have it apart this afternoon, but i just wanted some ideas as to maybe the cause of all of this before i go back and talk to him. Thanks

 

its probably that cv locked up. take that axle out and see if the other spins, make sure your diff is alright.

 

I am hoping it is the cv. I have a complete new axle to go in. If not the cv, I could live with it being something in the diff. I just hope its not inside the motor.

 

The shop wasnt able to get to my bike, so i went and picked it up this morning. And magically, it moves just fine. Drained the rear diff when i got it home amd found just a little bit of metal shavings. Also drained the engine oil again and it looked fine as well. I'm glad that it is working fine now but i almost wish i would have found something wrong to fix. Seems odd to just lock up and then free up with nothing being done to it.

 

mmm i would still have a look at the cv like old mate GN posted cause some things not right , and it will let you down on the track

 

Using an impact will cause unnecessary wear on the one way bearing.
Buy the motion pro clutch holding tool to torque it properly.

Metal shavings in an 2002 660 diff..... Check the pinion bearing for side to side play.
I've read some threads about the pinion bearing retainer nut backing off (which is inside the diff) and chewing things up.

I don't think there is any way to check that nut without opening the diff and looking to see if the nut is rubbing on the back of the pinion gear.

Go for a ride, change the diff oil again, if it still has shavings, then open it up. If you catch it before it destroys anything else its a fairly cheap fix. Bearing, seal, retorque the nut.

Wait too long and it will be, bearing, seal, bearing carrier with retaining nut, possibly ring and pinion, may also wreck the case.

 

As for the locking up, if a piece of the cage inside the cv joint broke off it could still work fine until that piece makes its way into one of the channels, where it will bind the joint causing it to lock.

 

The metal shavings were minimum, didnt seem too out of the ordinary. My previous arctic cat would have much more every oil change and all the cat people would tell me that was normal.

As for the cv, i am doing the conversion to 03 and up axles so i should have that problem solved shortly. If anybody else is looking to do this conversion, you will need both the bearing carrier and wheel hub from 03 and up. Also, the axle nut on the newer axles is larger than the one on the 02 models. That nut is the only thing holding me back right now.

Thanks for all the help.

 

You got the the axle swap figured out. Sweet.

What was the difference with the hubs?
I know how the bearing carriers are different, just curious what you found with the hubs?

 

I honestly dont remember the difference with the hubs. I was so mad about the nut not fitting that i just left it and went in and watched football the rest of the day lol. I think the hub of the 02 model is a little wider. I'll inspect it a little more when i find me some axle nuts for the newer axles. Thanks for all your help with the swap. It was a great starting point to help me get the swap figured out.

 

Wow, now I remember.
2002 axles are longer from the diff to the inside face of the bearing carrier.

The hub on the 2002 is about 1/4 inch wider.

I had way too many axle parts flying around when I tried to put 2002 axles in my 2002 grizzly without knowing the bearings and hubs had been switched by the previous owner.

2002 axle with 2003+ hub, axle bottoms out before bearing carrier can be bolted up.

2002 axle in the 2003+ hub and bearing with spacer trying to make it work.

2002 axle 2003 axle 2003 bearing

I forgot I started a thread over a year ago "axle identification help" when I did all this nonsense.

Well glad you figured it out either way

 

Wow, dont you just love when someone does something to their grizz and then dont tell you when you buy it. Would have made your project a lot easier knowing what had been done.

Just like you mentioned, the 2002 axle is too long to use with the 03 up bearing carrier and hub and the 2003 up axles are too short to use with the 02 carrier and hub.

 

Yeah for sure it would have been nice to know.
When I broke my first axle I thought oh goody I have a 2002.
So I didn't even bother looking for axles.
Then Grizzlysituation ended up offering me his after he finished doing his lift, that came with all new axles. So I waited for that.
Then they came, didn't have any time off to work on it, so I waited some more.

Took the axles I got from nick and pulled them apart to re pack with new grease.

Put them in the bike........ Ummm wtf lol
Pissed around for a couple days trying to make something work.
Ended up ordering a "high strength" from part discounter.

Broke the axle in September, got it fixed in February lol

 

I'm looking for a good used rear end for my 2006 Yamaha grizzly 660 4wd... Can someone help me please ???