I had the fuse for the solenoid that shifts the quad from 2 to 4wd blow today. I replaced the fuse and it shifted back to 2wd but as soon as I shifted back to 4wd it blew again. Any suggestions or ideas before I take it back to the dealer.

 

Check the wireing from the switch down to front axle .

 

The wire to the soleniod is shorted to ground or the solenoid it's self is overloaded when shifting into 4wd, anyway should't be to hard to troubleshoot.

 

It just so happens that recently my 2003 Kodiak was doing this same exact thing. If you put a 5 amp fuse in place of the 3 amp it will probably start working fine. My Kodiak is still under factory warranty so I took mine back to the dealership. They ended up replacing the servo motor, I got the bike back and it did it again. They replaced the servo motor again along with the switch itself, so far so good. My buddy is an atv mechanic at the dealership I bought my Kodiak from. The second time I brought the bike back he said he had never seen the Kodiaks come in with this type of repetitive problem before, so he called a service rep. The service rep told him they had only seen it happen a few times and that some of the shops were just telling owners to replace the 3 amp fuse with a 5 amp. He did pull apart the servo motor both times when he was replacing them and said the inside was burnt/blackend up. The servo motor runs about $285, so I am glad mine is still under warranty since mine was replaced twice so far. I found that the two times that this happened on mine I was in 4 wheel drive with the lights on running about 30-40 MPH. If your Kodiak is still under warranty definately take it back, if not pop a 5 amp fuse in and you should be fine. I have only had my Kodiak back about a week so far, I will get a better chance to put it through the ringer here in a week or two, but for now it is fine.

 

Thanks for the info. The atv is still under warranty so it is definately going back to the dealer. It is due its first service so while they have it in the shop for that they will look at the servo problem. Did it take long for your shop to get a servo from Yamaha or did they have one in stock? Thanks again.

 

The first time, when they replaced the servo motor only, they had the bike for about a week. The second time, when they replaced the switch and the servo motor, it was gone about a week and a half. The second time they had it they spent a little more time trouble shooting the problem so they ended up taking a little longer. The servo motor is an easy swap, so most of the wait is on the part coming from Yamaha. I got about another 3 months left on the factory warranty, but the dealership said that since this problem occured while it was under warranty and it had been a re-occuring problem, they would cover the servo motor for a while after the factory warranty ran out.

 

Well, it looks like I will be taking the Kodiak back to the dealer also. It is blowing the fuse again, it was working ok for awhile but had it in 4wd last night and out it went. I popped a 5 amp fuse in it and the servo started working. So they obviously have not figured the problem out yet. I'll keep you posted.

 

Sounds like a wiring problem, or they have a real big problem with servo motors. Maybe the aftermarket will come up with a better solution for when these machines are out of warranty, such as installing a Warn 424 unit in place of the electrical unit.

 

Sorry to hear about you ongoing problem with blowing the fuse. My dealer called today and said that the servo on our quad was the problem and a new one is on order. He said it should take 5-7 days for parts from yamaha. I hope this fixes the problem the first time and we don't go through continuous problems like you are having.

 

Anyone else having this problem on a recently purchased Kodiak?[img]i/expressions/face-icon-small-shocked.gif[/img]