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2004 Yamaha Grizzly 660 Starter Not Engaging

Ajmboy

By Ajmboy
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Posted by Ajmboy,

Got it fixed today, ended up replacing the starter clutch bearing and so far starts every time. The lobes look a little worn but nothing major except that it causes intermittent no starts/cranks. I still have to put the plastics on but will wait till tomorrow to make sure nothing is leaking and it’s running good.   
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Ajmboy Grand Master

Ajmboy

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@Frank Angerano great advice! The fastest I can get the gasket is on eBay 

https://www.ebay.com/p/1127879845?iid=124148034979

Amazon is no longer 2 days to me and really sucks lately because of everything going on. 

I had to drain the antifreeze to get the cover off. Didn’t touch the water pump, just disconnected the coolant hoses.

 

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Ajmboy Grand Master

Ajmboy

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2 hours ago, Frank Angerano said:

Have you priced it ?  Should be no more then $60 bucks and a lot of them come with the gasket. 

The OEM is higher priced so I ordered an aftermarket with bolts for $28. https://www.ebay.com/itm/Starter-Clutch-One-Way-Bearing-Sprag-For-Yamaha-5Lp-15590-00-00/291688226787?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649

I have two gaskets coming so I'm going to put the aftermarket in with the existing gear and see how it goes. If it doesn't last, I'll open it up again and replace with OE and a new gear or get an aftermarket kit. 

I also ordered an OE oil pump chain because I think mine is stretched: https://www.ebay.com/itm/YAMAHA-CHAIN-2002-2008-YFM660-GRIZZLY-2004-2008-YXR660-RHINO-94581-94070-00/273490598260?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649

I didn't have a puller around and ordered this one for $24: https://www.ebay.com/itm/Tusk-Flywheel-Puller-Remover-35mm-YAMAHA-GRIZZLY-350-400-450-550-660-700-rotor/172483117628?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649

@Frank Angerano Thanks for your offer on sending the puller but shiping there and back, it was worth to just get one and have it on hand part of my "collection" 😁

 

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Ajmboy Grand Master

Ajmboy

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I haven't even started to put this back together yet. Got shifted to other projects like landscaping....and because walmart hasn't sent me my oil, I now have to run out! I ordered it on April 9th and still delayed...

image.png.0877d980d2ecd3cfb13ff9cd9f195513.png

 

So I decided to also order it for pick up and will probably run out Friday or Saturday because I need to go to a bunch of other places...was trying to avoid going to the store unless I absolutely had to and they have the best price...with corona its a process...mask, gloves, disinfect everything, shower 15 times...

image.png.cfab599bad8f4ca12ac8fd4f898abf8d.png

 

Hopefully back together this weekend.

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Ajmboy Grand Master

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Figured I’d replace the bearing now than in the winter if it goes. Replaced the oil pump chain but the old one and new had same amount of play so probably didn’t need to do that.... 

Got the flywheel off and couldn’t find my 6mm allen socket to take off the bearing, so ran to Lowes and bought a metric set. Go it off and went to put the new one on and realized it’s wrong! I must have messed up in my searching on eBay and bought the wrong one. Cleaned the old one and reinstalled. Put it back together and fired up after cranking for a bit after messing with the choke, almost like timing off but then started. Still need to put antifreeze in it, no way to do it without disconnecting coolant hoses. 

I cleaned the bearing and inspected. We’ll see how long it lasts. At first when it wouldn’t start I thought maybe I messed something up. I’ll get back at it tomorrow hopefully. 

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Ajmboy Grand Master

Ajmboy

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Got it fixed today, ended up replacing the starter clutch bearing and so far starts every time. The lobes look a little worn but nothing major except that it causes intermittent no starts/cranks. I still have to put the plastics on but will wait till tomorrow to make sure nothing is leaking and it’s running good. 
 

29050279-D4E4-4EEA-8C0D-AF56B27A7DF6.thumb.jpeg.e24b97a627ae2edd51aa6fc642444171.jpeg

9BBD2965-A5E3-4A24-BC32-31A508AFEA64.thumb.jpeg.a18a00811b11273ed757a183c8f80114.jpeg

A525BB6D-68AD-4A6F-A81B-DD5F4C176585.thumb.jpeg.8e713f1fafa9d9de5510309e2130b927.jpeg

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