If you have recently bought a 2003 Kodiak 4x4, you will definately want to run the heck out of it in 4 wheel drive while it is still under warranty. I have been having an ongoing problem with mine. I was riding the Kodiak in 4 wheel drive and noticed my 4x4 light was not lit. I push the button to switch it back to two wheel drive, but nothing happend. I noticed the fuse was blown so I pop another 3 amp fuse in it and hit the button. It would do the switch from 4wd to 2wd but would blow the 3 amp fuse each time it made the switch. I then popped a 5 amp fuse in and the servo motor worked fine. I took the bike in to the dealership, they replaced the servo motor and said the inside was all burnt up. I again ran the kodiak in 4wd and for awhile it was ok, but again did the same thing a few weeks later. So, the dealership again replaced the servo motor along with the 2wd-4wd switch and the wiring that goes from the switch to the servo motor. I again had it a few weeks and continued to ride it in 4wd and it again it does the same thing. So that's three times this has happed, I know of someone else on this forum that has had the exact same problem with his Kodiak as well. Now, I have to wait because the motor is on back order. My good friend is the head mechanic at the dealership, he thinks it may be the motor (design flaw) that Yamaha is putting into the Kodiaks, Yamaha says, of course, its not. So, I just wanted to give everyone who has bought a 2003 Kodiak a heads up. Make sure to run the heck out of your Kodiak in 4wd while it is still under warranty. I think my next step will be to look into what the lemon laws are here in Ohio. Has anyone else here had any problems with your servo motor?

 

We just got back from picking up my wifes 400 kodiak from the dealer for the same problem. He said that they have had to replace the servo on a few of the 03 kodiak 400's so far. They haven't replaced any yet on a 450 but I would guess that they use the same servo. Hopefully Yamaha just had a problem with the supplier of the servo and it is not a design problem. Good luck with yours and hopefully ours will hold up as well.

 

I would think they are the same servo motors (400 and 450) too. Hopefully you don't get the ongoing problem that I have had. My mechanic friend thought it was kind of suspicious that the servo's were on backorder all of the sudden. He is wondering if maybe Yamaha is starting to get more complaints and are starting to take a look at the current servo motors before they send anymore out. He said he won't be surprised if Yamaha issues a bulletin on this particular problem. The next thing they are going to try is of course another servo motor, and then they are going to replace another set of wires that run from the servo to something else other than the switch. I did call Yahama and complained. Yamaha said that they will cover the servo until the problem is fixed regardless of when the factory warranty runs out, but it's still a pain to be with out it and also to have to keep running back and forth to the dealer everytime it does this. I just wanted to let everyone know to make sure they run there Kodiaks in 4wd a good amount of time before there warranty runs out.

 

I had a grizzly 660 03 model with same problem , first off I found that shift fork in front differential was molded wrong , replaced with a good one, it worked pretty well but again blew fuse and 4 wheel drive didnt work correctly, Yamaha replaced front differential and it works good.

 

Yamaha seems to fluck up a fair bit. I just ordered a choke cable (bad from the factory) and a water pump(same deal) alltogether it'll cost me over $200 to fix (out of my pocket) so i highly doubt it that i'll buy another first year model agoin, at least from yamaha (those SHOULD have been recalled!-afterall they fixed the problem the next year or two)

 

Vmaxer, so they ended up having to replace the differential on yours. How long has it been since they did that? I'm guessing they will eventually end up doing that to mine as well. I doubt this new set of wiring they are going to replace is going to get anything accomplished, I hope it does, but I highly doubt it.

 

The grizzly and kodiak,have a different gearcase but who knows if that is is where your problem is, sure sounds like we are having the same type of problem though.!!!!

 

Well, I got the Kodiak back last night, sooner than I had figured on. The dealership ordered another motor to put on reserve in case this new one goes out. So, I guess time will tell, I'll keep you posted.

 

I HAD THE SAME PROBLEM WITH THE SERVO. THE NEW ONE WAS REPLACED LAST WEEK. WHEN I HIT THE 4WD BUTTON I HEAR THE SERVO WORKING AND THE 4WD LIGHT GOES ON AND OFF BUT IT SOMETIMES REFUSES TO COME OUT OF 4WD.

 

[img]i/expressions/face-icon-small-mad.gif[/img] WELL...IT HAPPENED AGAIN. MY SERVO IS BAD. RODE IT TWICE SINCE I GOT THE NEW ONE PUT IN. IT BLOWS BOTH 3 AMP AND 5 AMP FUSES. I HOPE YAMAHA WILL DO SOMETHING ABOUT THIS. IT TOOK THEM 2 WEEKS TO FIX IT LAST TIME. LETS SEE WHAT HAPPENS THIS TIME.