I RECENTLY BOUGHT A USED 99 YAMAHA GRIZZLY 600. THE STARTER IS STAYING ENGAGED TOO LONG. I REPLACED THE STARTER WITH A BRAND NEW YAMAHA STARTER(200.00) IT STILL DOES IT. ANY IDEAS?

 

Bad starter switch, your switch could be hanging up slightly. Test it by checkind voltage at the starter solenoid for dropping out when you let go of the starter button. Post back if it is not the problem.

 

Yeah...get a new switch but try and clean yours first

 

This is for a 03 Grizz 660, it may not be exactly the same but it may be close enough for what you need.

STARTING CIRCUIT OPERATION
The starting circuit on this model consists of
the starter motor, starter relay, rear brake
switch, rear brake switch CDI unit and gear
position switch. If the main switch is on and the
engine stop switch is in the RUN position, the
starter motor can be operated only if:
1 Main fuse
2 Battery
3 Starter relay
4 Starter motor
5 Start switch
6 Ignition fuse
7 Engine stop switch
8 CDI unit
9 Rear brake switch
0 Gear position switch
È TO MAIN SWITCH
É FROM MAIN SWITCH

The transmission is in neutral (the neutral
switch is closed).
or

The transmission is in park (the rear brake
switch is closed).

The rear brake lever is pulled (the rear
brake switch is closed).

EB803020
TROUBLESHOOTING
Procedure
Check:
1.Fuse (main, ignition)
2.Battery
3.Starter motor
4.Starter relay
5.Main switch
6.Engine stop switch
7.Gear position switch
IF THE STARTER MOTOR FAILS TO OPERATE:
8.Rear brake switch
9.Start switch
10.Diode
11.Wiring connection (the entire starting system)
NOTE:

Remove the following part(s) before troubleshooting:
1)Seat
2)Fuel tank side panels
3)Fuel tank
4)Air cleaner case
5)Front carrier
6)Front fender panel

Use the following special tool(s) for troubleshooting.
Pocket tester:
P/N. YU-03112, 90890-03112
EB802011
CONTINUITY
1.Fuse (main, ignition)
Refer to “CHECKING THE SWITCH”.
NO CONTINUITY
Replace the fuse.
EB802012
CORRECT
2.Battery

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
INCORRECT

Clean the battery terminals.

Recharge or replace the battery.

TURNS
3.Starter motor

Connect the battery positive terminal 1
and starter motor cable 2 using a jumper
lead 3 .

Check the operation of the starter motor.
*
WARNING

A wire that is used as a jumper lead must
have the equivalent capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.

This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.
*
DOES NOT TURN
Repair or replace the starter motor.
4.Starter relay

Remove the starter relay from the wire harness.

Connect the pocket tester (Ω × 1) and the
battery (12 V) to the starter relay terminals.
CONTINUITY
Battery (+) terminal →
Blue/White terminal 1
Battery (–) terminal →
Blue/Black terminal 2
Tester (+) lead → Red terminal 3
Tester (–) lead → Black terminal 4

Check the starter relay for continuity.
*
NO CONTINUITY
Replace the starter relay.

C0NTINUITY
CORRECT
5.Main switch
Refer to “CHECKING THE SWITCH”.
*
INCORRECT
Replace the main switch.
CORRECT
6.Engine stop switch
Refer to “CHECKING THE SWITCH”.
INCORRECT
Replace the handlebar switch (right).
CORRECT
7.Gear position switch
Refer to “CHECKING THE SWITCH”.
INCORRECT
Replace the gear position switch.
CORRECT
8.Rear brake switch
Refer to “CHECKING THE SWITCH”.
*
INCORRECT
Replace the rear brake switch.

CORRECT
9.Start switch
Refer to “CHECKING THE SWITCH”.
INCORRECT
Replace the handlebar switch (left).
CORRECT
10.Diode

Remove the diode from the coupler.

Connect the pocket tester (Ω × 1) to the
diode terminals as shown.

Check the diode for continuity as follows.
Tester positive probe →
Blue/Red 1
Tester negative probe →
Black/Yellow 2
Continuity
Tester positive probe →
Black/Yellow 2
Tester negative probe →
Blue/Red 1
No continuity
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the left
chart will be reversed.
INCORRECT
Replace the diode.
EB803028
11.Wiring connection

Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
Properly connect the starting system.