One of those lucky things happened to me...I acquired a non-running Kodiak 4x4. So off I go on a trek to try to get it as back to decent running/stock condition as I can. Stock is not the best word to use, but usable is much more appropriate.


It was muddy as crap. I broke one of the skid plate bolts off just trying to get it apart to clean it.


At one time it was snorkeled. I will probably never use a snorkel, but I don't know if I will remove the piping yet or not. There was an electrical issue that I have been tracking down. Step one was the battery.


Put a multi-meter on it....2 volts. Time to change. $53.00 later, I have a battery showing 13 volts. No start. I take a look and find this...and thought it was my issue.

I still can't find a 2006 wiring map on the internet, so I have been using a 2003 diagram which is pretty close (and could be the exact same for all I know). I did replace the starter relay (free from a friend) as it showed external signs of where a spark jumped. It still didn't start. So, I pulled the starter...pulled it apart to find this:


So now I am in search for a new starter. While I wait for parts to arrive (that I haven't even ordered yet) I pulled the gas tank to drain and clean it. The Kodiak sat for 2 years, so I knew the gas was bad. The aroma of the gas confirmed. So I tried to drain it...and nothing came out the petcock. So I pulled it and took it apart. This is what it looked like inside it.

New petcock is about $25 from my local dealer. I wanted it now even though you can find them cheaper online. At least it is a Yamaha part I guess.

So now I wait for a new starter to show up and hope that the 'fix list' will diminish. I'll keep y'all posted.

 

Why not clean the petcock out? Also every used starter I have taken apart had that much carbon in the endcap, some a lot more, you just blow it out with an air line. The problems come with worn brushes, loose magnets or a burnt commutator, if it just needs new brushes, they are 1/4 the price of a starter.

 

The petcock had essentially welded itself shut. That gunk is like concrete. I normally can blow out or use a bottle brush to clean a petcock, but this one wasn't budging. The fuel filters attached to the top had disintegrated. For me, it was just easier to replace.

Where is a good source for the brushes? I don't mind rebuilding it, there is always a good time to learn, and for me that time is now.

 

Brush kits here for less than 20 bucks or the complete starter for $67.DB Electrical - New Yamaha ATV Starter YFM400 KODIAK FM 400 93-98 GOLD YA105 SMU0065 Or even cheaper.http://www.dbelectrical.com/p-6686-n...0-660-atv.aspx

 

Good luck on the rebuild. the best feeling in the world will be scratching off the last item on your checklist.
I'll be following this thread, keeping my fingers crossed for you.

Going thru something similar with my son's recently acquired 1990 Firebird.
It's not in the best shape but if you've ever seen the movie Christine, you'll understand how he feels about this car.
I just hope it doesn't try to kill me. LOL

 

Lots of parts around on ebay as well. Its really a 450 Grizzly but Yamaha did a name change in 2007 same when they dropped the Bruin name.

Not even a change in 2012 2012 Yamaha Grizzly 450 Auto. 4x4 EPS ATVs except eps is a option.

 

Alright guys, I need some help. This project got pushed to the back of the shop last year and now it is time to pull it back out.


Here is where I am at trying to get it started.
New relay, new fuses, cleaned connections, new battery, new starter. I still have the red wire not attached in the first post on the connector to the starter relay. I haven't been able to find a wiring map to figure out where it goes/what it does. I have had the engine turning over with it unattached though.


It had the pull cord hole welded shut at one time, so I can't even try to pull start it. I need to find a used pull cord and cover to see if I can get it pull started. Most of the time, I hit the start button and nothing. Any thoughts? Does the starter button go out often? Any good way to test it?

 

This is the wire I cannot ID.

 

The start buttons can be susceptible to having dirt and corrosion cause less of function. I have cleaned out many a starter button in my time. Seeing that it was in a muddy condition, it would be worth it to pull the button apart and clean it. Not sure on that wire. Do you get spark when the start does work?

 

I do get spark. I put a tester in between the wire and the plug and it would light up. I will have to pull it apart and clean it then, and see if that helps. I really wish I could figure out what that broken wire does or at least find a 2006 wiring diagram to figure it out.


When the button did engage the starter, it would not continuously run. It would run for a few turns, and then silence...nothing. I could hit the button here and there and it would turn the starter for a second or two and stop again. Nothing like normal when the starter would run as long as the button was down.