Yamaha 2004 Grizzly 660 Auto 4x4 - Answered Questions & Fixed issues

1. Check the INTAKE valve clearance!!!! 2. Check for an air leak 3. Install a new spark plug and air filter!! 4. Check the compression.. 5. Have the carb professionally cleaned and set!! >> Once you have sone all these steps.. repost to me if this did not fix it!!

Yamaha Grizzly 660 2002 2008 get one of these..If you are going to try the repair yourself.... .this is serious, .... there MIGHT be damaged components that need to be inspected by a professional.

sounds like your reverse sensor is bad and the cdi limits rpms while in reverse as a safety thing.

Most likely a switch issue. there is a switch in the brake handle as well.

K, Linkage probably needs adjusted. Check the attached links,instruction and guides, Good luck "I hope this helped you out, if so let me know by pressing the helpful button. Check out some of my other posts if you need more tips and info." 2006 GRIZZLY 660 MOD HELP and SHIFTER ISSUES http://www.yamaha-motor.com/assets/service/manuals/2008/lit-11626-21-03_griz660_all_1498.pdf

reverse sensor is bad or the wire to it is grounding somewhere

I have the same problem but I have contacted grizzly about it & they have told me it is standard

Sounds like worn valve guides. If compression is good it would be oil seeping through guides while engine is still.

Sounds like there dif is gone or drive shaft

Hey Anon, this is NOT something to "try and learn" how to do..find a professional that is will to tutor you when you do this for the first time! It COULD save you A LOT of $$$$!!!!!

If you have good spark then it's most likely a fuel issue, anything off of idle is dealing with the main jet and metering needle, clean jet and check needle for excessive wear.

Check the fuel flow through the tank valve. There are screens inside the tank that may be blocked and restricting flow.

.004 intake .005 ext

must hold brake, use the foot brake!

Question edited for clarity. https://www.google.com/search?q=2004+honda+rancher+350+fuel+line+diagram Free Service Manuals

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It is inappropriate to explain how to possibly steal a machine on this public site.

Assembling a recoil system on a Polaris 400 Xplorer involves several steps. While I can't provide an actual diagram here, I can outline the general steps involved in assembling a recoil system:

1. Preparation: Ensure you have all the necessary parts for the recoil assembly including the recoil starter, recoil housing, recoil spring, and any other associated parts.
2. Mounting the Recoil Housing: Begin by mounting the recoil housing onto the engine. It typically bolts onto the engine casing.
3. Inserting the Recoil Starter: Place the recoil starter mechanism into the recoil housing. It usually fits into grooves or mounts within the housing.
4. Attaching the Recoil Spring: Connect one end of the recoil spring to the recoil starter mechanism and the other end to a fixed point within the recoil housing. This provides the tension necessary for the recoil starter to function properly.
5. Installing the Pull Cord: Thread the pull cord through the hole in the recoil starter mechanism and tie a knot at the end to secure it. Wind the pull cord around the recoil starter as per the manufacturer's instructions.
6. Testing: Before completely sealing the recoil housing, give the recoil starter a few pulls to ensure it functions smoothly and retracts properly.
7. Final Assembly: Once you're satisfied with the recoil assembly, bolt down any remaining covers or components to secure the recoil system in place.

Always consult the specific service manual for your Polaris 400 Xplorer for detailed instructions and diagrams tailored to your exact model. Additionally, if you're unsure about any step, it's best to seek assistance from a professional mechanic or someone experienced with small engine repair.

take off the horn unit power it direct if it works its ok, if not replace, next step wire a small bulb into the horn wires and press the button if it lights the switch is ok, if you have a circuit tester put one end on the battery ground and check for power in the horn wires if their is power there put the lead on battery positive and press the horn button if there is no power their the switch or wiring is faulty

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