Sonders

I took it for a ride a little bit ago and rode it as far as last rime when it overheated. It didn’t overheat this time, but fan still never came on. It spit some anti freeze out of the overflow tube. I checked anti freeze level once I got back and the overflow tank is sitting at the low mark. So not sure if it just had extra in the radiator and was spitting the extra out or what.

Still scratching my head on this stupid thing. I replaced the fan relay circuit and fan relay switch and still no fan. I unplugged the fan with the bike running and hooked test light to the plug. Shouldn’t the blue wire have power to it? Or does it only send power when it needs to turn the fan on? Maybe I didn’t run it long enough?? The harness below is what comes from main wiring harness and runs to the relay switch and fan and down to 4wd actuator. I checked the wires on the backside of this harness with bike running as well and the only wire that has power is the red wire. Does that sound right?

Yeah Tahj that air inlet tube was just replaced on mine. Previous owner busted it right before where it clamps onto CV housing at some point and had it ghetto rigged up with part of a plastic bottle and lots of duct tape 🙄. I ordered a new pipe and installed on it. Just one of the many messes I’ve fixed/replaced on this thing.

Ha. It only looks clean because I spent a week scrubbing everything on it and unplugging/cleaning every connection on the bike as seen from one of my first posts in the thread of the bike torn down. I’ve lost track of all the hours I’ve spent on this thing since purchasing. Believe me it looked awful underneath all the panels when I first brought it home. I’ve regretted my purchase since bringing it home with all the crap that I’ve found wrong since tearing into it. At this point I just want to get it on the freakin road and get some actual use out of it.

Found the relay and put tester on it. First time I checked it I had power on both sides of it and power at the fan sensor switch. I messed around with some other stuff in the garage and then checked them again a few minutes later and had no power. So they must be going out I’d assume. I’ve not seen a relay like this before so hopefully I can order new one through parts pages. I’ll replace it along with the fan sensor switch and see what happens.

True, didn’t think about that. I have a test light. I’ll give that a try.

Thanks for that info Frank. I ran out and checked the high temp switch by grounding it out and light came on just as you said. I also checked the fuse box and all fuses were good. I saw the circuit breaker for fan, but I don’t have a tester to check it. Hopefully the fan switch is the issue and will fix it when it arrives this week. Guess I better pick up some anti-freeze this week as well.

Thanks Frank. I went ahead and ordered a fan sensor relay. I’ll mess with the temp sensor tomorrow evening and check the fuses.

#14 from the diagram is actually a fan sensor switch from what I could find looking around online. I’ll try grounding temp sensor like you suggested to see what happens. May go ahead and replace the fan sensor switch as it’s cheap.

Looking at parts diagram #13 & 14 are both listed as thermo switch assemblies. 13 looks to go in top of cylinder head and 14 looks like it goes to the radiator. I’m assuming 14 is the thermostat. I’ve seen the single wire sensor on top of cylinder head that you are talking about. I’ll check it first. Guess I’m going to be sinking even more money into this dang thing.

Finally got a chance to go for a ride today. Made it about 3 miles and it overheated and shut off on me 🤦🏼‍♂️. I’m beyond frustrated at this point. I’ve got the front end stripped off of it now as I was looking where anti-freeze was coming from. It’s overflowing out of the vent tube up front. I had it running in the garage once it cooled off just to watch to see what it did. The fan never comes on. When should it kick on? I thought maybe it wasn’t working so I took it off and wired it straight to a battery and it comes right on and spins fine, so that’s not the problem. Not sure what else to check at this point.

Nigel, my 01' Kodiak has the same setup you are describing. Here are the part #'s from Yamaha OEM parts site if that helps any. 5GH-14458-01-00 (replaces part # 5GH-14458-00-00) GUIDE $58.99 $40.13 7 In-Stock 11 1UY-14468-00-00 PLATE,ELEMENT FITTING $12.49 $8.49 10+ In-Stock 12 5GH-14451-00-00 ELEMENT, AIR CLEANER $19.99 $14.23 10+ In-Stock I take that back, I did a search under your model and came up with these part #'s instead: 1YW-14458-01-00 (replaces part # 1Y 1UY-14468-00-00 PLATE,ELEMENT FITTING $12.49 $8.49 W-14458-00-00) 1YW-14451-00-00 ELEMENT, AIR CLEANER $14.99 $10.19 GUIDE $59.99 $40.79

Jacob, my first thought was to use cutting wheel and put a slice in the screw head to get a philips head on it, then I remembered my dremel crapped out on me this past winter and I hadn’t replaced it yet. Anyways, was out in the garage a little bit ago working on another project and happened to notice gas puddled on top of engine underneath the carb as my side body panels are still off. Bottom of the carb is wet from gas leaking out so I’m assuming the bowl gasket is shot. I knew I should have went ahead and replaced it while it was apart. Will it hurt to use the gasket off the oem carb since it’s new?

finally, it's alive! I fooled around with the oem carb some more last night. My needle nose vise grips weren't cutting it while trying to remove last screw from fuel bowl. By dumb luck a small pocket size pair of vise grips ended up doing the trick in removing it. I cleaned the jets on it and reassembled and installed it back on the quad. First push of the button and it fired right up, go figure. I took it for a ride about a mile down the road and it didn't spit or sputter or cut out at all. I'll ride it some more this weekend when I get some free time and see how it does. On another note; the exhaust sounds like crap and I may need to look into a new exhaust pipe for it. I've never messed with atv exhaust before so that will be something completely new to me. I'll start a new thread on that when I decide to start digging into it more; for now I just want to ride it some. Thanks for all the help/replies Frank & Jacob.

I agree with you Jacob. As soon as I’m able to get the last stripped screw out of fuel bowl of oem carb I plan to go through it and rebuild it. I mainly got the aftermarket one for the throttle cable cover and the throttle adjuster (they were missing from oem one when I bought it). No way would I toss the oem carb.

Yeah I checked what the oem carb was set on and it was 2 -1/4 turns. I wonder if I can get a replacement fuel/air mixture screw needle that has the turn screw sticking out bottom that is easier to adjust. Busy the next few evening, so will be the weekend before I get a chance to mess with it anymore. Man I just want to get this darn thing on the road. I also started to disassemble the oem carb lastnight to check it over but 2 of the damn screws on bowl had stripped heads so couldn't get them off. Was just an overall frustrating evening; I finally had to just call it a night.

ok, had some time to mess with this last night but didn't have much luck. Warning, long read to follow: I found a small right angle screwdriver in tool kit I keep in my car to use on fuel/air mix screw on carb. I felt around for the screw to get the screwdriver on it but couldn't find the head of it. I got frustrated and ended up removing the carb to get a better look. The screw is a weird one, or it has cap over it like you mentioned earlier in the thread Frank. Keep in mind this is a new aftermarket carb (pic of what I was seeing below). I didn't know what to do with that, so I robbed a few parts off of the new carb and put on the oem carb and stuck the oem carb on the quad. Once oem carb was installed I tried firing it up and it just cranked but wouldn't fire. After a few tries the starter stayed engaged and kept cranking over so I had to disconnect the battery. This was a new problem I've not encountered before. I installed the original starter relay solenoid to see if that made a difference and it did as the starter only cycled when I hit the starter button like it was supposed to (weird). I tried starting a few more times and still no luck getting it to fire. Next I checked for spark by removing spark plug and touching it to the cylinder head and boy did it have plenty of spark as it shocked the crap out of me. I removed the oem carb and swapped the few parts back to new aftermarket carb and installed it back on the quad and wouldn't you know it, it fired right up and idled as smooth as can be. I rode it up and down the driveway a few times to see how it ran and still same issue with it cutting out as I got on the throttle. So basically back to square one where I started. Any thoughts on what I'm looking at on the aftermarket carb air/fuel mixture? Also attached is a pic of the quad put back together minus the tank and engine side covers.

Located fuel/air mixture screw on carb last night, but not sure how the heck I'm going to get to it to adjust. I had a pocket screwdriver, but still couldn't get to it well enough to turn the screw any. Going to have to regroup and try again tonight if I can find a shorter screwdriver.

thanks, I'll take a look when I get home this evening.

on top of what I originally paid for it, if I have all my receipts all added up I'm currently at $1,600. So not terrible, It will need a few more items eventually, but once I get the carb adjusted correctly I'm going to run it as is for awhile. I'll have to take a closer look, when I get home, but do you know where exactly the air fuel mixture screw is on the carb on these quads?

have this thing mostly back together and had it running this weekend. I ran it up and down the driveway a few times and noticed it's cutting out which leads me to believe the carb will need to be adjusted. I just need to figure out correct way to do that. All the issues I had from original post have been taken care of, except for speedometer cable. I had one on order at local dealer but it is backordered. Looks like that fix will be waiting awhile. It was having issue with going into Low and High range when I first got it as well, but that ended up being because the idle was too high. I've got it idled down lower and it shifts into gear no problem. I also need to get a fuel gauge for the tank sometime and install as it's missing and just has a homemade plug where the gauge goes. I thought I got a good deal on this thing with the issues it had, but boy are the parts receipts adding up.......

got bottom engine guard cut down to fit and installed this weekend. About ready to fire this thing back up. I do have a question. Speedometer doesn't work so I ordered a new speedo cable. Does anybody know the correct process of disconnecting it from the engine housing and installing the new one? I see there are a few gears in the speedo housing and I don't want to risk tearing anything up.

That's what I was thinking Frank. Going to give bleeding the rear a try sometime this week. It was missing the engine guard/skid plate when I got it. A new oem one was about $60. I found a few used ones on ebay for $15 but are for 03' and up models and are a full 1 piece plate. I went ahead and got one and am going to try cutting it down to just the middle piece that I need. Or remove the front plate that is still on mine and see if I can get the full 1 piece plate to mount up on it. We'll see what happens when it arrives later this week.

I also need to figure out how to adjust the rear brake. I'm wondering if I can just bleed it like I did the fronts as the foot pedal is close to bottomed out currently. I'm a little confused though as I found the service manual for it on this site and as I looked through it, it shows it having a rear drum brake. Mine however has rear disc brake.