Thanks for the detailed adjuster information. I have a 2004 660 and find the two locking nuts can normally be accessed by removing just the side cover . The bottom ball joint thread was seized in the rod so it required heat to loosen so the black plastic cover needed to come off. It's important not to damage as it looks like the rod and ball joints are part of the entire shifter assembly.
Great video! Thanks for going through so much work to show us what the shifting mechanism looks like and how it works. Great job. I learned every thing I need to know.
All the Way from Texas want to give you a very big Thank You. I have a couple of the kind bikes with these shifters and this was a big help in seeing how the adjustments are made. Really enjoy your helpful work in your videos . Have a blessed new Year.
Andy mechanic I have an 06 grizzly 660. Just replaced clutch and was riding and adjusted left brake lever, it seemed to make the bike not go into low and a hard time with most really.. I don’t see how they are really relevant. I made adjustments as you did in the video, it helped temporarily I’ll have to give it another go
My 450 was new Oct 2016 and has the same low gear hesitation since new, not as bad as one in post. I engage low then slightly blip throttle to engage then drive away. First service due in April and had intended to mention this, but I may have a look myself. My bike is well oiled including gear linkage at 900 miles. Thank you for most informative posts
+billalbion Hi, thanks for the feedback, pleased you found the video helpful. The adjustment is relatively easy though I found that only a very small change in the rod length made quite a difference to gear selection so just make fine adjustments each time until it engages smoothly. Cheers Andy
I just bought a 2023 it's kind of hard to gears Seeing others were having this problem also But other say their is fine should I take it back to the dealer
Seems exactly my problem with the Kodiak 4x4 but that adjustment did not fix it. The end selector works well and all light correlate. So I’ll open the gear selector to seek inside.
That was a great video. I have a 01 Kodiak and I can't get it into reverse. I think it is the brake do hicky that is preventing it from moving backwards. I do wish you had spoken more about that. My question is, what if I eliminate it physically. I can appreciate that I won't have any indication as to the gear I'm in but I don't care.
Andy, Thanks for the vid. It will help me a lot. I'm interested in how you had the bike on the lift. Did you just stradle the lift with the bike? Did you put anything under it like wood blocks or just let the lift come in contat with the undersisde? I have a 2000 Kodiak and am hoping I can lift it like you did the one in this vid.
Hi, I usually use wooden blocks so I can still get the oil drain pan in for when doing an oil change. One at the front & another just forward of the rear final drive, timbers going across the hoist bed. Cheers Andy
My issue with my Grizzly, is when you put it in park, the indicator light doesn't light up. No light on the dash means it won't start. This helps me understand the adjustment
Hey Andy my bike is hard to get into neutral well it is in neutral but the light doesn't come on and doesn't start I have to run the gear leaver up and back and sometimes it will turn on neutral light and can start it but then once it is hot and stops and try to get that light back on to start, no chance I can seem to get it going again would it be what your talking about or could it be some electrical fault senser or something that's causing it thanks mate let me no please Andrew qld Australia
Excellent video. My 2007 grizzly 700 you really have to keep pressure on the shifter then bump the throttle to get it to go into low range. Every other gear shifts perfect. Wonder if this linkage adjustment would cure it
My Grizzly 700 is a 2009, and is stuck in park. I always used the foot brake to sift. So that interlock cable is also attached to the foot brake and hand brake lever? I'm a little confused sorry? Any insight. Thanks Mate 😊👍
1998 yamaha grizzly 600, won't take reverse at all, won't even enter the position for it. It will go back toward it 90% of the way but then it's like you just hit a wall. The brake cable that runs to the safety release could be potentially frozen up, can there be other problems or if it is the cable can that be bypassed?
Possibly. Just ensure the rivets holding the two rose joints on the external link rod haven't come loose Also, it the idle too high - this will cause the centrifugal clutch to start to transfer drive so will be harder & jurky to get into gear Hope this helps. Cheers Andy
Hi, it really should be a motorcycle oil as the transmission relies on good lubrication too & car oils are designed just for engine demands. My preference is Yamalube which is Yamaha's own oil. Hope this helps. Cheers Andy
I’m having the same issue but it’s doing the clicking and refusal to go into gear at all positions. Would that be just an adjustment like this or does it sound like more of an internal problem? Also, once in gear, it won’t stay in place unless hand brake is held. Almost as if it’s idling too high or something.
Yep. Check idle, if too high then centrifugal clutch will be dragging which will make it hard to engage gears & bike will be driven even when completely off the throttle. Just reduce idle at carb & see if that helps. Cheers Andy
Andy, I'm not sure if that particular year of bike has this problem, but from 03-07 on the 660 the shifter is slightly different but I imagine are similar internals. Either way, I had to do this for a friend before on an 04 660. Take the shifter assemble off the bike, leaving the shift rod connected, just unbolt shift rod from the motor and there are 3 bolts on the shifter that hold it on and the brake interlock for reverse and park just unscrews. Take the shift knob off and then the boot. Once you have that done, on the opposite side of the shift rod there should be a push nut/speed nut that goes over the shaft that the shifter and shift rod are connected to that needs to be removed. You will probably break that push nut getting it off but once you do, pull the shaft out of the assembly and you will notice that it is square stock with rounded edges that insert inside the plastic housing of the shifter. This is where the problem arises, normal wear causes too large of a tolerance and thus causes the shifting problem, solution is to take a pepsi can or similar and cut a small piece off to go over the shaft you just removed and reinsert into the shifter. (keep notice as to location of shift rod before you removed it. Once you do this, assembly is reverse of disassembly. Bike should shift better or as good as it did new. Did this 8 years ago the first time, never had a problem since and never had to adjust the shift rod length fist or last. Hope this may help someone as it took a bit of time to find out when it would have just slipped out of position when the locknuts never moved...
+Scott Barron That's excellent advice, I'm sure plenty of viewers will find that very helpful. If I get an older 660 come in to the workshop I'll be sure to do a video covering your fix. The later one I worked on had rose joints either end of the external shift rod. Customer had said that it had always been a little hard to engage low gear but it had got worse in recent months? No wear at the rose joints so can only think the motor has settled down on its mounts maybe (can't remember if it's rubber mounted like vikings or not to be fair?) Anyway, thanks for taking your time to write such a detailed post. Pleased you liked the video. Cheers Andy
Andy Mechanic Hey got one more just like the gear selector. I put it in L give it a little gas . It jump and back in to H.. and some time it want catch no gear at all uk . I have to garb it and pull it in gear?
I was riding a few weeks ago and my trans blew... that’s what I’m thinking at least bc when I would give it a little gas it would want to try to go then it would make a loud bang/clank how should I go abt this bc I’m gonna take it apart here in a day or 2
Hey man! Thanks for the video.. quick question, in the beginning there was some knocking noises once you lifted the bike off idle. Did the adjustment help that as well?
You seem to be a dang good mechanic, id like to ask your opinion, I have a kodiak 700 eps se (2020) i have my diff light flashing, temp and engine light on... i was told it was a bad relay.. my atv has 88.8 miles on it.. and advise would be appreciated. Im not a mechanic and just got into the yahama family... everything works as it should, just those lights, im afraid to ride it entil i know whats up Thanks so much
Hey Andy. Nice video and explanation. I’m in Canada just north of Toronto. My quad is a 2013 chironex 550 bandito which I believe is a Chinese knock off of Yamaha. Engine looks like Yamaha. Only 620 km on the bike. Forward hi and lo engagement no issue. Reverse on the other hand has always been a “clunking” engagement and takes several attempts to get positive engage. When not fully warmed up it’s not uncommon for it to jump out of reverse when increasing throttle. Gets better when fully warmed up. Do u think it’s the shift selector rod needing adjustment. I’ll be a subscriber.Any thoughts..Thx in advance for any advice u could could provide. Keithkmrg
Hi Keith, damn I hate it when the Chinese copy other brands. It's just not right as Yamaha did all the development work etc. Anyway, yes, this could well be an external push rod adjustment issue. However, if you over adjust it you may affect low ratio selection at the opposite end of the gear levers travel. Just make small adjustments and see how you get on. Welcome aboard :-) Cheers Andy
I would like to know if you have any videos on the foot brake cleaning and adjustment?? My 2013 grizzly 700 is pretty stiff, the foot brake will not actuate up and down. Any help by chance? Thanks Gus
Hello. I have an 06 450 kodiak. It will go through all of the gears fine but when I try to put it in neutral to start it the light wont come one so I can start it. But sometimes it will come on and sometimes it wont. Any advice to the cluprit?
Yes, there is a neutral light switch on the gearbox, the brass plunger will have worn down - will need replacing...that's the most likely reason so check that first. Cheers Andy
great video Andy , just recently having a problem with my gear shift on cold mornings , shiftier is basically locked up and takes a lot of force to move it into any position but does come out of it and shifts with no problems / normal , so when it sits over night in cold tempertures seems to be the worst , where can i start to look to take care of this problem , thank you !! 2003 Kodiak 450
+Michael Winkelsas Hmmmm.....unlikely to be external linkage but check all pivots are lubed and move freely. You may have to adjust a little or it could be low or need an oil change?
Make sure your idle speed is not too high. They don’t like to change gears if the belts are moving too fast. My 2006 Grizzly 660 needs to idle between 1450 and 1550 rpms. Anything higher (above 1800 rpms) and it is hard to come out of gear and bangs when it does.
I have a 2008 Yamaha 660 grizzly it will go forward and reverse it is stuck in low gear in forward will not go in high I can put it in high and the dish reads it's in high gear but it still in low plz help
Sorry, no videos on that yet. Yes, it's a wet brake from memory - bit like a motorcycle clutch Pack. It is adjustable but if you have run out of adjustment then it'll likely need new friction plated installing. Cheers Andy
i have a 2014 450 grizzly i notice you show the safety switch on the gear shifer if i take that pin off can i still us my shifter and my break i think its a pain
I have a lady selling a 04 kodiak 450 4x4 she says it needs a new shifter bar because u have to adjust it softly put it in gear and it will stay she’s asking 2600 I have 2800 too my name is it a quick easy fix ?
I always thought these quads use transmission fluid Like ATF DW-1. Much like honda Automatic. i guess they use the engine oil in the case so basically the Engine and transmission share the same oil Or im i mistaken?
14+ thousand miles on it and it's not but a few years old? Wow! Just where I live most quads are only around 2k maybe 4kmiles. I wouldn't buy one myself used with more than a couple thousand miles on the clock 😂. Eastern Us just most bikes don't get alot of miles, woods riding mostly. However I'm sure there are bikes with 10k on them in much better shape than some I've mentioned with 2k on then. Guess it's neither here nor there. Cheers.
My red reverse light is on and I have my bike In natural but my green neutral light is not showing and I can not start my engine . When I play with my gear controller back and forth the lights go back to normal operation, but when I put it into high gear or any position the red reverse light comes on again. Any suggestions to help me ?
Hi, yes, it's likely the brass pin on the reverse light switch (on engine casing) has worn down - it will need to be replaced. Let me know how you get on. Cheers Andy
Hi Andy, I’ve just bought a 2007 Yamaha Grizzly 450 from the UK MOD and am in the process of trying to give it some well earned TLC. One/Two problems I’m experiencing surround gear Selection/Engagement. (1) Occasionally when trying to select REVERSE the gear fails to engage and I get a clattering sound/shuddering. That said if I then select DRIVE HIGH followed by REVERSE, the gear engages. Do you think this is likely to be a External Gear Selector issue or Internal? (2) Possibly connected to Item 1. The Gear Indicators on the Display often don’t show which gear is selected. Any thoughts / suggestions? Regards Stephen
+Stephen Salter hi Stephen, it sounds very much like the external gear linkage is either poorly adjusted or the rose joints are worn causing excessive play. I don't think it's an internal fault.
Hi Andy, having had a further look i'd appreciate some more advice regarding the Gear Selector issue. Checked: Bushes for play but they appear Ok With Engine off moved selector into each position (50% of time LED's did not work) With engine on tried engaging forward/reverse, resulting in chatter. Noticed Engine Tick Over Quite High Reduced Tick Over With Engine On Engaged Forward / Reverse without difficulty yet LED's still only working 50% of time. Any suggestions? Regards Stephen
Hi, well it could be a number if possible faults. Firstly & most likely, there is a switch on the side of the engine that has a rotary type contact pad. These can wear out like in an ignition barrel. So I'd unplug it from the loom and test it with a multimeter or test light - you'll need a wiring diagram. If this turned out okay then bridge the wires one at a time in the plug on the loom - you should see each gear light illuminate with each wire bridged. If not then could be a loom fault or possibly an issue inside the dash. Let me know how you get on. Cheers Andy
Thank you for you valuable knowledge. If some day you are interested to find out how I did repair a stripped oil drain threads with a broken lip on a Yamaha Kodiak 400 2001; I will be pleased to share my successful repair with you Thanks again
Ok I’ll let you know how I make out also after I installed the shifter the cable that runs out of the shifter assembly over to the foot brake is really loose and can’t seem to tighten it is it supposed to be really tight??
Okay. Usually on the left front lower chassis rail behind left front wheel. Otherwise send me the model code sticker - under the seat. White sticker with ????-???
Andy .. what it means if my dash say R.. but my will turn forward instead.. and when I put it in H... my wheels turn back ward?? Plz help.. I turn something??? Freaking out.. hope I didn't mess up nun.
Yes.. when I was turning it by hand.. the dash says reverse and a red warning light like overhearing light came on to.. I was trying to find neutral that's why I was turning by hand please help Andy and did I mess up something
Hmmmm.....I think your bike may actually be more like our old Bear Tracker 250. do you manually. change gears with your left foot or is it a shifter for Forward, Reverse, neutral etc on the left side of the fuel tank? very different transmission if that's the case...
Not sure about that choice of White Lithium grease.........it has no penetrating properties. Also, regarding those cowl clips, they are one time use only. Drill a small hole through the plastic post and install a little hitch pin. Just like the copper paste, makes it a little nicer for the next guy getting in there. Lastly, invest in some ratcheting wrenches my friend.
hello Andy. I need some help. I own a 2005 Yamaha Kodiak 450. I was driving it the other day and while traveling about 30MPH, the bike locked up like in gear and came to a Immediate stop so i turned it off and started it back up and it wouldn't go into high or reverse. when I would move the gear selector into high or reverse it would not move! I would put it in neutral and it would drive forward but only forward. It will not drive in any other gear and I know it shouldn't drive in neutral. Do you have any idea of what it might be or what I could check? I personally do not have the money to pay someone else to fix it, I would like to fix it myself. I seriously would appreciate any feedback.
+Kevin Talley Sure thing. I sounds like an internal gearbox fault. I had a similar thing happen on a Yamaha warrior 350. One of the gears siezed to the shaft due to poor lubrication. It was 2nd gear and the bike could be used in 2nd but no other gear. I'm busy fabricating all day today but will take a look at the gearbox schematic tomorrow and try give you some ideas....
Andy Mechanic thanks so much for taking the time to respond. I seriously appreciate the help with this. This is a bike I recently bought for me and my family to ride and enjoy. I want to fix it myself especially since we unfortunately don't have the money to have a mechanic fix it. what would I need to check first? do I need to take apart my cvt cover and look at it? or what step would I need to take first?
+Kevin Talley if it's an internal gearbox fault then, unfortunately, it will require the removal of the engine from the frame but don't do that just yet. You could check the engine oil level & condition first. Maybe even drain the engine oil and inspect for metal particles.
Andy Mechanic well I've actually recently checked the oil and added the amount that I needed. every time I checked the oil about every day it has checked good with a good color and no metal shavings. I've also recently changed the air filter and the starter solenoid and I've cleaned my grounds as well. should I check my cvt? or where my gear rod attaches to my actual gear selector mounted on my transmission?
Andy Mechanic well I've actually recently checked the oil and added the amount that I needed. every time I checked the oil about every day it has checked good with a good color and no metal shavings. I've also recently changed the air filter and the starter solenoid and I've cleaned my grounds as well. should I check my cvt? or where my gear rod attaches to my actual gear selector mounted on my transmission?
Hey! Your videos are great. I'm a small engines mechanic and these videos are really helpful. Caruso Lombardi is a soccer coach. Sarch for some images on google and you'll understand everything! Greetings from Argentina.
In some areas of the World different words are adopted for the same item. This is an example of that, here in New Zealand an ATV can be referred to as any of the following: ATV, quad, bike, quad bike, four wheeler amongst others You'll find this is actually a quite common occurance for various objects. Anyway, hope this helps explain why I referred to an ATV as a 'bike'. Andy
Thanks for the detailed adjuster information. I have a 2004 660 and find the two locking nuts can normally be accessed by removing just the side cover . The bottom ball joint thread was seized in the rod so it required heat to loosen so the black plastic cover needed to come off. It's important not to damage as it looks like the rod and ball joints are part of the entire shifter assembly.
Great video! Thanks for going through so much work to show us what the shifting mechanism looks like and how it works. Great job. I learned every thing I need to know.
All the Way from Texas want to give you a very big Thank You. I have a couple of the kind bikes with these shifters and this was a big help in seeing how the adjustments are made. Really enjoy your helpful work in your videos . Have a blessed new Year.
This saved my life. I have the exact same problem in my wife's 2012.
Excellent video. Wow. I can sure tell you are a professional instructor!
Thanks Brian :-)
Another great video Mike.
This is something I need doing on my MOD 450 Grizzly.
Thanks
Andy mechanic I have an 06 grizzly 660. Just replaced clutch and was riding and adjusted left brake lever, it seemed to make the bike not go into low and a hard time with most really.. I don’t see how they are really relevant. I made adjustments as you did in the video, it helped temporarily I’ll have to give it another go
The 700 Grizzly is almost the same setup....Thanks for the help
Just done this with my grizzly 450 irs, made a big difference just wants the rod fine tuning, goes into park and reverse every time
Tks Andy. I have to do this to my 700 Grizz tomorrow.
My 450 was new Oct 2016 and has the same low gear hesitation since new, not as bad as one in post. I engage low then slightly blip throttle to engage then drive away. First service due in April and had intended to mention this, but I may have a look myself. My bike is well oiled including gear linkage at 900 miles. Thank you for most informative posts
+billalbion Hi, thanks for the feedback, pleased you found the video helpful.
The adjustment is relatively easy though I found that only a very small change in the rod length made quite a difference to gear selection so just make fine adjustments each time until it engages smoothly.
Cheers Andy
Yeah mine I have to goose the throttle to engage it in gear. But also coasting down a hill sounds like my gearbox starts clinking
I just bought a 2023 it's kind of hard to gears
Seeing others were having this problem also
But other say their is fine
should I take it back to the dealer
Seems exactly my problem with the Kodiak 4x4 but that adjustment did not fix it.
The end selector works well and all light correlate.
So I’ll open the gear selector to seek inside.
That was a great video. I have a 01 Kodiak and I can't get it into reverse. I think it is the brake do hicky that is preventing it from moving backwards. I do wish you had spoken more about that. My question is, what if I eliminate it physically. I can appreciate that I won't have any indication as to the gear I'm in but I don't care.
Andy, Thanks for the vid. It will help me a lot. I'm interested in how you had the bike on the lift. Did you just stradle the lift with the bike? Did you put anything under it like wood blocks or just let the lift come in contat with the undersisde? I have a 2000 Kodiak and am hoping I can lift it like you did the one in this vid.
Hi, I usually use wooden blocks so I can still get the oil drain pan in for when doing an oil change. One at the front & another just forward of the rear final drive, timbers going across the hoist bed.
Cheers Andy
@@AndyMechanic Thank you.
My issue with my Grizzly, is when you put it in park, the indicator light doesn't light up. No light on the dash means it won't start. This helps me understand the adjustment
Hey Andy my bike is hard to get into neutral well it is in neutral but the light doesn't come on and doesn't start I have to run the gear leaver up and back and sometimes it will turn on neutral light and can start it but then once it is hot and stops and try to get that light back on to start, no chance I can seem to get it going again would it be what your talking about or could it be some electrical fault senser or something that's causing it thanks mate let me no please Andrew qld Australia
Excellent video. My 2007 grizzly 700 you really have to keep pressure on the shifter then bump the throttle to get it to go into low range. Every other gear shifts perfect. Wonder if this linkage adjustment would cure it
Definitely worth a try. Thanks Andy
My Grizzly 700 is a 2009, and is stuck in park. I always used the foot brake to sift. So that interlock cable is also attached to the foot brake and hand brake lever? I'm a little confused sorry?
Any insight.
Thanks Mate 😊👍
1998 yamaha grizzly 600, won't take reverse at all, won't even enter the position for it. It will go back toward it 90% of the way but then it's like you just hit a wall. The brake cable that runs to the safety release could be potentially frozen up, can there be other problems or if it is the cable can that be bypassed?
Good youtube wish I would have seen sooner. I have adjusted as far as will go and still hesitates into low looks like I have to check gear box
Possibly. Just ensure the rivets holding the two rose joints on the external link rod haven't come loose
Also, it the idle too high - this will cause the centrifugal clutch to start to transfer drive so will be harder & jurky to get into gear
Hope this helps. Cheers Andy
Hi Andy,
Quick question!!!!!
Can I use any 10W40 semi synthetic oil for my Grizz 450
Hi, it really should be a motorcycle oil as the transmission relies on good lubrication too & car oils are designed just for engine demands.
My preference is Yamalube which is Yamaha's own oil.
Hope this helps. Cheers Andy
I’m having the same issue but it’s doing the clicking and refusal to go into gear at all positions. Would that be just an adjustment like this or does it sound like more of an internal problem? Also, once in gear, it won’t stay in place unless hand brake is held. Almost as if it’s idling too high or something.
Yep. Check idle, if too high then centrifugal clutch will be dragging which will make it hard to engage gears & bike will be driven even when completely off the throttle. Just reduce idle at carb & see if that helps.
Cheers Andy
I'm having a similar problem with my 2012 550 grizzly (power steering) is it basically the same style gear selector adjustment set up?
Hi Andy are the 450 and 550 quad selector arms the same lengths
Andy, I'm not sure if that particular year of bike has this problem, but from 03-07 on the 660 the shifter is slightly different but I imagine are similar internals. Either way, I had to do this for a friend before on an 04 660. Take the shifter assemble off the bike, leaving the shift rod connected, just unbolt shift rod from the motor and there are 3 bolts on the shifter that hold it on and the brake interlock for reverse and park just unscrews. Take the shift knob off and then the boot. Once you have that done, on the opposite side of the shift rod there should be a push nut/speed nut that goes over the shaft that the shifter and shift rod are connected to that needs to be removed. You will probably break that push nut getting it off but once you do, pull the shaft out of the assembly and you will notice that it is square stock with rounded edges that insert inside the plastic housing of the shifter. This is where the problem arises, normal wear causes too large of a tolerance and thus causes the shifting problem, solution is to take a pepsi can or similar and cut a small piece off to go over the shaft you just removed and reinsert into the shifter. (keep notice as to location of shift rod before you removed it. Once you do this, assembly is reverse of disassembly. Bike should shift better or as good as it did new. Did this 8 years ago the first time, never had a problem since and never had to adjust the shift rod length fist or last.
Hope this may help someone as it took a bit of time to find out when it would have just slipped out of position when the locknuts never moved...
+Scott Barron That's excellent advice, I'm sure plenty of viewers will find that very helpful. If I get an older 660 come in to the workshop I'll be sure to do a video covering your fix.
The later one I worked on had rose joints either end of the external shift rod. Customer had said that it had always been a little hard to engage low gear but it had got worse in recent months? No wear at the rose joints so can only think the motor has settled down on its mounts maybe (can't remember if it's rubber mounted like vikings or not to be fair?)
Anyway, thanks for taking your time to write such a detailed post. Pleased you liked the video. Cheers Andy
Scott Barron
Hey having problem with a back fair on my Yamaha grizzly 660 need help?
+Jason Williams hi, what do you mean by a 'back fair'?
Andy Mechanic
Hey got one more just like the gear selector. I put it in L give it a little gas . It jump and back in to H.. and some time it want catch no gear at all uk . I have to garb it and pull it in gear?
Andy Mechanic
Hey andy . When adjusting the front shifter? Whats the best gear to start with? Pls feedback
I was riding a few weeks ago and my trans blew... that’s what I’m thinking at least bc when I would give it a little gas it would want to try to go then it would make a loud bang/clank how should I go abt this bc I’m gonna take it apart here in a day or 2
Hey man! Thanks for the video.. quick question, in the beginning there was some knocking noises once you lifted the bike off idle. Did the adjustment help that as well?
I have a 2013 Yamaha kodiak that gear shifter freezes in the cold. Thoughts? Once the bike warms up the shifter works fine.
You seem to be a dang good mechanic, id like to ask your opinion,
I have a kodiak 700 eps se (2020) i have my diff light flashing, temp and engine light on... i was told it was a bad relay.. my atv has 88.8 miles on it.. and advise would be appreciated. Im not a mechanic and just got into the yahama family... everything works as it should, just those lights, im afraid to ride it entil i know whats up
Thanks so much
Hey Andy. Nice video and explanation. I’m in Canada just north of Toronto. My quad is a 2013 chironex 550 bandito which I believe is a Chinese knock off of Yamaha. Engine looks like Yamaha. Only 620 km on the bike. Forward hi and lo engagement no issue. Reverse on the other hand has always been a “clunking” engagement and takes several attempts to get positive engage. When not fully warmed up it’s not uncommon for it to jump out of reverse when increasing throttle. Gets better when fully warmed up. Do u think it’s the shift selector rod needing adjustment. I’ll be a subscriber.Any thoughts..Thx in advance for any advice u could could provide. Keithkmrg
Hi Keith, damn I hate it when the Chinese copy other brands. It's just not right as Yamaha did all the development work etc.
Anyway, yes, this could well be an external push rod adjustment issue. However, if you over adjust it you may affect low ratio selection at the opposite end of the gear levers travel. Just make small adjustments and see how you get on.
Welcome aboard :-)
Cheers
Andy
@@AndyMechanic I have a 2004 Yamaha and I can't even move my lever to reverse. What is your take on what needs to be fixed
I have an 02 kodiack and just yesterday I found the entire shifting lever wont engage into any gear, it only has about 400 miles in it?
I would like to know if you have any videos on the foot brake cleaning and adjustment?? My 2013 grizzly 700 is pretty stiff, the foot brake will not actuate up and down. Any help by chance? Thanks Gus
Hello. I have an 06 450 kodiak. It will go through all of the gears fine but when I try to put it in neutral to start it the light wont come one so I can start it. But sometimes it will come on and sometimes it wont. Any advice to the cluprit?
Yes, there is a neutral light switch on the gearbox, the brass plunger will have worn down - will need replacing...that's the most likely reason so check that first. Cheers Andy
Silly question: What is that left shifter actually adjusting? Does it swap the gear ratio in the transfer case?
Yes, it switches a mechanical gearbox after the CVT in the driveline. Cheers Andy
great video Andy , just recently having a problem with my gear shift on cold mornings , shiftier is basically locked up and takes a lot of force to move it into any position but does come out of it and shifts with no problems / normal , so when it sits over night in cold tempertures seems to be the worst , where can i start to look to take care of this problem , thank you !! 2003 Kodiak 450
+Michael Winkelsas Hmmmm.....unlikely to be external linkage but check all pivots are lubed and move freely. You may have to adjust a little or it could be low or need an oil change?
Make sure your idle speed is not too high. They don’t like to change gears if the belts are moving too fast. My 2006 Grizzly 660 needs to idle between 1450 and 1550 rpms. Anything higher (above 1800 rpms) and it is hard to come out of gear and bangs when it does.
I have a 2008 Yamaha 660 grizzly it will go forward and reverse it is stuck in low gear in forward will not go in high I can put it in high and the dish reads it's in high gear but it still in low plz help
Same grizzly, rear brake check. I think it's inline with the drive shift. Any videos?
Sorry, no videos on that yet. Yes, it's a wet brake from memory - bit like a motorcycle clutch Pack. It is adjustable but if you have run out of adjustment then it'll likely need new friction plated installing.
Cheers Andy
i have a 2014 450 grizzly i notice you show the safety switch on the gear shifer if i take that pin off can i still us my shifter and my break i think its a pain
I have a lady selling a 04 kodiak 450 4x4 she says it needs a new shifter bar because u have to adjust it softly put it in gear and it will stay she’s asking 2600 I have 2800 too my name is it a quick easy fix ?
Yes, the external shift linkage is easy to replace & not too expensive for replacement parts :-)
Cheers Andy
Very helpful. Thank you.
I always thought these quads use transmission fluid Like ATF DW-1. Much like honda Automatic. i guess they use the engine oil in the case so basically the Engine and transmission share the same oil Or im i mistaken?
Same oil on these now :-)
Andy Mechanic ok thank you good to know 🙂
14+ thousand miles on it and it's not but a few years old? Wow! Just where I live most quads are only around 2k maybe 4kmiles. I wouldn't buy one myself used with more than a couple thousand miles on the clock 😂. Eastern Us just most bikes don't get alot of miles, woods riding mostly. However I'm sure there are bikes with 10k on them in much better shape than some I've mentioned with 2k on then. Guess it's neither here nor there. Cheers.
Buenas tardes tengo esa moto y kisiera saber si me pudiera explicar cómo ajustar el freno trasero
Awesome video
My red reverse light is on and I have my bike In natural but my green neutral light is not showing and I can not start my engine . When I play with my gear controller back and forth the lights go back to normal operation, but when I put it into high gear or any position the red reverse light comes on again. Any suggestions to help me ?
Hi, yes, it's likely the brass pin on the reverse light switch (on engine casing) has worn down - it will need to be replaced.
Let me know how you get on. Cheers Andy
Thank you so very much I will replace it a.s.a.p will let you know.
What city you based mate?
I’m in Nz with a kodiak with issues
Auckland for work & Taupo is where I live, yeah, I know, long commute! Lol
@@AndyMechanic taupo is great!
Okay. Why not send me an email explaining what the problem is & where you are based?
Looks like a bit of fiddling but it's better than the new ones I have been looking at , all solenoid driven selector from a control module. Yikes :)
Mine annoying it select the gears but the reverse light also comes on aswell when in high and low. So limits the revs. Doing my head in
Easy fix - replace reverse light switch on gearbox casing - brass plunger wears down.
Andy
I have a problem witha Yamaha bruin the second i put in gear it drives off by itself but the motor isn't rev high
It does drive off in foward in neutral
Hmmmm.....it sounds like the Sprag or one way bearing has siezed on the shaft...
Hi Andy,
I’ve just bought a 2007 Yamaha Grizzly 450 from the UK MOD and am in the process of trying to give it some well earned TLC.
One/Two problems I’m experiencing surround gear Selection/Engagement.
(1) Occasionally when trying to select REVERSE the gear fails to engage and I get a clattering sound/shuddering. That said if I then select DRIVE HIGH followed by REVERSE, the gear engages. Do you think this is likely to be a External Gear Selector issue or Internal?
(2) Possibly connected to Item 1. The Gear Indicators on the Display often don’t show which gear is selected.
Any thoughts / suggestions?
Regards
Stephen
+Stephen Salter hi Stephen, it sounds very much like the external gear linkage is either poorly adjusted or the rose joints are worn causing excessive play. I don't think it's an internal fault.
Andy,
Thanks for the rapid response.
Back at work now fixing Wind Farms. Will enjoy tinkering next weekend.
Kindest regards
Stephen
Hi Andy,
having had a further look i'd appreciate some more advice regarding the Gear Selector issue.
Checked:
Bushes for play but they appear Ok
With Engine off moved selector into each position (50% of time LED's did not work)
With engine on tried engaging forward/reverse, resulting in chatter.
Noticed Engine Tick Over Quite High
Reduced Tick Over
With Engine On Engaged Forward / Reverse without difficulty
yet LED's still only working 50% of time.
Any suggestions?
Regards
Stephen
Awesome, thanks a lot!
2003 kodiak 450 the shift lights won’t work all the time when shifting what is the problem
Hi, well it could be a number if possible faults.
Firstly & most likely, there is a switch on the side of the engine that has a rotary type contact pad. These can wear out like in an ignition barrel. So I'd unplug it from the loom and test it with a multimeter or test light - you'll need a wiring diagram. If this turned out okay then bridge the wires one at a time in the plug on the loom - you should see each gear light illuminate with each wire bridged. If not then could be a loom fault or possibly an issue inside the dash.
Let me know how you get on. Cheers Andy
Andy Mechanic thank you I will give that a try
8
Thank you for you valuable knowledge. If some day you are interested to find out how I did repair a stripped oil drain threads with a broken lip on a Yamaha Kodiak 400 2001; I will be pleased to share my successful repair with you
Thanks again
Hey any I just installed a new shifter assembly on my grizzly 660 I can’t seem to find a good spot to start from any suggestions????
I'd start in low ratio at the lever & gearbox. Adjust the rod up in that position then see if you can get reverse
If not then just make small adjustments until you can get both low & reverse relatively easily
Ok I’ll let you know how I make out also after I installed the shifter the cable that runs out of the shifter assembly over to the foot brake is really loose and can’t seem to tighten it is it supposed to be really tight??
Jason again... can u plz help me to find a service repair manual.... for my.. Yamaha grizzly 660 ultramatic 4x4 2004????
Sure thing. Send me an email with the full VIN number: andymechanic@live.co.uk
I have look for it but haven't find it .. any idea what or where to look for it?
@@AndyMechanic I've tried looking for it but haven't found it any idea where to look for it or will it stayed out to me?
Okay. Usually on the left front lower chassis rail behind left front wheel. Otherwise send me the model code sticker - under the seat. White sticker with ????-???
@@AndyMechanic ok this what I got. Dk If it's the right thing....
5km-82590-10
09-6 y p 0005..
Thanks
Andy .. what it means if my dash say R.. but my will turn forward instead.. and when I put it in H... my wheels turn back ward?? Plz help.. I turn something??? Freaking out.. hope I didn't mess up nun.
Is it the lights on the dash that read wrong or the gear lever's position that doesn't match the direction the bike goes in?
Yes.. when I was turning it by hand.. the dash says reverse and a red warning light like overhearing light came on to.. I was trying to find neutral that's why I was turning by hand please help Andy and did I mess up something
This is most odd indeed. Have you removed the rod between the gear lever and the engine?
@@AndyMechanic talking about by the gas tank like on your video
Then I think you got the push rod linkage the wrong way up....
Thank you tonz!!
I have a Yamaha bruin 250 was told it was gear box it wines when u push it when take it off I roll free
That's fine - sprag clutch will engage when you push the bike - this is the part that provides engine braking on deceleration & descents.
Cheers Andy
@@AndyMechanic when I mess with the gear selector and pushing on it forward it makes a clunking noise
Hmmmm.....I think your bike may actually be more like our old Bear Tracker 250. do you manually. change gears with your left foot or is it a shifter for Forward, Reverse, neutral etc on the left side of the fuel tank? very different transmission if that's the case...
@@AndyMechanic yes
@@AndyMechanic here is my link ua-cam.com/video/oPn6uv8LJxg/v-deo.html
Not sure about that choice of White Lithium grease.........it has no penetrating properties. Also, regarding those cowl clips, they are one time use only. Drill a small hole through the plastic post and install a little hitch pin. Just like the copper paste, makes it a little nicer for the next guy getting in there. Lastly, invest in some ratcheting wrenches my friend.
hello Andy. I need some help. I own a 2005 Yamaha Kodiak 450. I was driving it the other day and while traveling about 30MPH, the bike locked up like in gear and came to a Immediate stop so i turned it off and started it back up and it wouldn't go into high or reverse. when I would move the gear selector into high or reverse it would not move! I would put it in neutral and it would drive forward but only forward. It will not drive in any other gear and I know it shouldn't drive in neutral. Do you have any idea of what it might be or what I could check? I personally do not have the money to pay someone else to fix it, I would like to fix it myself. I seriously would appreciate any feedback.
+Kevin Talley Sure thing. I sounds like an internal gearbox fault. I had a similar thing happen on a Yamaha warrior 350. One of the gears siezed to the shaft due to poor lubrication. It was 2nd gear and the bike could be used in 2nd but no other gear. I'm busy fabricating all day today but will take a look at the gearbox schematic tomorrow and try give you some ideas....
Andy Mechanic thanks so much for taking the time to respond. I seriously appreciate the help with this. This is a bike I recently bought for me and my family to ride and enjoy. I want to fix it myself especially since we unfortunately don't have the money to have a mechanic fix it. what would I need to check first? do I need to take apart my cvt cover and look at it? or what step would I need to take first?
+Kevin Talley if it's an internal gearbox fault then, unfortunately, it will require the removal of the engine from the frame but don't do that just yet. You could check the engine oil level & condition first. Maybe even drain the engine oil and inspect for metal particles.
Andy Mechanic well I've actually recently checked the oil and added the amount that I needed. every time I checked the oil about every day it has checked good with a good color and no metal shavings. I've also recently changed the air filter and the starter solenoid and I've cleaned my grounds as well. should I check my cvt?
or where my gear rod attaches to my actual gear selector mounted on my transmission?
Andy Mechanic well I've actually recently checked the oil and added the amount that I needed. every time I checked the oil about every day it has checked good with a good color and no metal shavings. I've also recently changed the air filter and the starter solenoid and I've cleaned my grounds as well. should I check my cvt?
or where my gear rod attaches to my actual gear selector mounted on my transmission?
yamaha big big 400 gear shift reverse repair
Andres nessito una consulta
Could this be the reason I can't get mine into reverse?
Yes. Highly likely :-)
Caruso Lombardi!!!!
+Jose Del Vecchio Thanks....I tried to translate but failed! Do you know what it translates into English??
Hey! Your videos are great. I'm a small engines mechanic and these videos are really helpful. Caruso Lombardi is a soccer coach. Sarch for some images on google and you'll understand everything! Greetings from Argentina.
Me atiendes en ru oportunidad
bike?? cant count eh...quad = 4 wheels bike = 2 wheels ..bi..vs quad...
In some areas of the World different words are adopted for the same item. This is an example of that, here in New Zealand an ATV can be referred to as any of the following:
ATV, quad, bike, quad bike, four wheeler amongst others
You'll find this is actually a quite common occurance for various objects.
Anyway, hope this helps explain why I referred to an ATV as a 'bike'.
Andy
@@AndyMechanic so can call my 2 wheel motorcyle a bike quad then??
You can call it anything you like.....lol
@@AndyMechanic oh well in any case. Tx for the informative video ...a job well done!!
Cheers Matey, pleased you found them helpful. Ride safe
Andy