i was riding with a guy today had a brand new 05 660 grizzly, about 40 minutes into the ride, he started climbing a hill when i noticed only one wheel turning going up, i had him pull over, and we found right at the cv boot, the metal cleanly snapped in half and flooping around uslessly, he had about 500 miles on the bike, i thought they fixed this problem for 05? is this not true?

 

Welcome to the club. next it will be your head lights. the switch get bumped mid way between high and low, too hot and the solder on the bulbs comes loose. now my right foot board is loose from the four mount bolts. better buy tools and parts.

 

sorry to burst it for ya but no one has "fixed" the axle problem on any IRS quad out there.....axles will always be a thing to deal with.....even Gorilla axles break.....so no it's not true that Yamaha "fixed this problem for 05"

 

mine broke on my 03 grizzly with 34 hrs on it and no warranty left,just bought an 06 on sat. hopefully this problem does not reoccur.

 

I've seen this a lot in my cv business. It appears they have over hardened the shafts. I guess in an attempt to make it stronger they have over done it. When metal shafts are case hardened too far they become brittle and will snap clean. If they are under hardened they will tear and leave a jagged edge. I have been working with my manufacture on a cure for this problem. I'll keep you posted.
Thanks,
Danny
"thecvman"

 

I'm pretty sure he was referring to the fact that the 03 models had more brittle axels than the 02 models and that they were beefed back up for the 04 models an up. And I'm pretty sure you knew that.

 

Hi Maddog,
No, this problem seems to have started with the 04 models. The problem with the 03 was that Yamaha went down significantly on the size of the outer cv joint housing and the internal parts of the joint. What typically happens is that the cage breaks, the ***** fall out, and your left with the inner race tumbling around inside the cv joint housing. Often when these come I find that the housing is still in good shape. We usually just replace the internal parts with a heavy duty chrome molly steel rebuild kit ($89.95) and new boot kit. This seems to remedy the problem. However, we do have replacement heavy duty replacement outer cv joints. On these we have increased the size of the housing and all of the internal parts by 33% and this to has proven to be a good permanent fix. PM if you'd like more details.

 

Thanks for the info/correction CVman, so the 03 issues were with actual axle breakage and the 04 and up have problems with the cv joints right? I have a friend with an 02 who hasnt had any problems as of yet, but he's still running small tires and no serious mud.

 

No, it's the 2003 with the cv joint issue. And the 2004 with the shaft problems.

 

Ahh, I had it flip flopped, thanks for clearing that up CVman.[img]i/expressions/face-icon-small-smile.gif[/img]