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    4wd Testing/Repair Step by Step with How-To Videos and Parts Links

    Troubleshooting the Yamaha 4wd System

    Here is a brief description of the components.

    Push button switch– Located on the handlebars on ATVs and the dash inside the cab on SxS’s. It let’s you switch from 2wd, 4wd, difflock with the push of a button.
    Relays– There are three relays that are responsible for the 4wd operation. On non diff lock models there are two. On ATV’s they’re located either under the seat next to your fusebox or under the front rack near the battery. On SxS’s, they’re located under the front hood in the battery box. If either of these are faulty it can cause problems so always check each one.
    Servo Assembly– The servo assembly is the black plastic assembly that’s mounted on the rear or side of your front differential. The servo “motor” (as shown in the pictures) is housed inside the black plastic assembly. This motor is usually the culprit for most 4wd related problems.
    While we do have complete servo assemblies available, there is no need to replace the entire assembly unless, A. you have somehow busted the black housing, B. the contacts are burnt inside the housing.
    99% of the time, you can remove and open the servo assembly (as shown in the videos) and return your assembly to new condition by replacing the motor only.
    There are four different types of servo assemblies. See the pictures below to identify which one is yours.

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    If you’ve purchased a servo motor and need help installing it, you can either watch the video titled replacing the servo motor at the bottom, or you can see the instructions below.
    Servo motor Installation Instructions:

    5KM/5GH instructions http://www.501parts.com/wp-content/u...uctions-3.docx
    3b4/1HP instructions http://www.501parts.com/wp-content/u...ructions3.docx


    Yamaha 4wd Troubleshooting Procedures

    I’ve included links to videos and parts. To see clips of the service manual pertaining to these tests look here.
    http://www.501parts.com/downloads/

    Problem 14wd not engaging, and when the push button is pressed nothing happens.

    Step 1– Check the fuse
    Step 2– Tap on the relays, one could be stuck (Two black with G8HN# on top and one white relay on most models.) Also check the connections on the servo and relays to make sure they’re connected properly.
    Step 3– Remove the front diff servo and proceed to test it (need two c batteries, T-45 tamper proof torx, and a 6 mm allen. Some use 10mm regular hex bolts) see this video.

    Testing the Servo
    https://www.youtube.com/watch?v=6BiuD5qfCw4

    If it tests bad, you can find a replacement motor here. http://www.501parts.com/shop/

    If you need the tools to remove it from the front diff you can find them at any parts store or you can order them here.
    http://www.501parts.com/product-cate...ecialty-tools/

    If it tests good, proceed to next step.
    Step 4– Test the three relays. You’ll need a multi-meter set on the lowest ohms setting usually 200, and a short run of wire to power up the relays. See this video.

    Testing the Relays
    Version 1 https://www.youtube.com/watch?v=phNDJka5tBA
    Version 2 https://www.youtube.com/watch?v=mP06edwS1_E

    If they test bad, you can find a replacement here.
    http://www.501parts.com/product-category/4wd-relays/

    If they test good, proceed to the next step.
    Step 5– Test the push button switch (you’ll need a multi-meter set to ohms) see these two videos.

    Testing the Push Button Switch Version 1
    https://www.youtube.com/watch?v=SGz2ZivOAj8


    Testing the Push Button Switch Version 2
    https://www.youtube.com/watch?v=Q-B83KDHX3c


    For a switch that tests bad, you could try cleaning it before buying one. See this video.

    Cleaning the 4wd Push Button Switch
    https://www.youtube.com/watch?v=rCNTXsrnRaQ


    If it tests bad after cleaning or you just want a new one, you can find it here.
    http://www.501parts.com/product-cate...tton-switches/

    If it tests good, proceed to the next step.
    Step 6– At this point you are certain your servo, relays, and switch are good. Next, you’ll want to start tracing wires looking for anything that’s frayed or broken. Common places for problems are under the fusebox on SxS’s, under the front racks on the ATV’s. Also check the connections under the relays beneath the seat on the ATV’s. You may have to untape and untie your wires to get to the problem.
    If you’ve tried all of this and still can’t get it going, you are welcome to call me at 501-658-0219 and I’ll help you through it.


    Problem 2I have replaced my servo motor or cleaned my servo assembly but now I’ve gotten it out of time and it’s not working properly.

    Step 1– One thing that will make life easier is to make sure not to bolt the servo up to the diff before you know for certain it’s working. You can plug the servo in and just let it hang to verify proper operation. You need to have three things synced to 2wd before plugging the servo in. 1. You should have the slide gear inside the diff to 2wd mode. 2wd is to the left if you’re sitting on the seat or to the front of the bike for those that go back and forth instead of left and right. On the Rhinos, move the slide gear to the right for 2wd if you are sitting in the seat. 2. Next, have the button in 2wd. 3. Finally, have the servo itself timed to 2wd. Here are videos on cleaning and timing the servo.


    Retiming the Servo (3B4/1HP)
    https://www.youtube.com/watch?v=IlXKTR46sSg


    Retiming the Servo (most common servo)
    https://www.youtube.com/watch?v=PqdEdRqxS6M


    Problem 3My ATV or SXS goes into 4wd or diff lock but will not come back out.

    Step 1– Try tapping on or swapping your two black relays and see what happens (if something changes then one is bad) proceed to test the relays to determine which one. You will break the clips off removing them. Almost no way around it.
    See these videos.

    Testing the Relays Version 1 and 2
    https://www.youtube.com/watch?v=phNDJka5tBA
    https://www.youtube.com/watch?v=mP06edwS1_E


    For a replacement look here. http://www.501parts.com/shop/


    Problem 4 The slider on my 4wd push button is stuck and will not go left and right with ease.

    Step 1- Watch this video.

    Cleaning and Repairing the 4wd Push Button Switch
    https://www.youtube.com/watch?v=rCNTXsrnRaQ

    It will show you how to disassemble and repair the slider.

    Problem 5I have a big ride tomorrow and I can’t get the 4wd to work. How do I manually put my ride in 4wd and just leave it until I can troubleshoot it?

    Despite what mode you may be stuck in 2wd,4wd, diff lock. You can manually put the diff into whatever mode you like. If I were going to pick a mode to leave the diff in for a ride, it would be 4wd.
    Step 1- Remove the servo from the front diff. You’ll see a slide gear inside the diff that moves left and right. Simply move that slide gear to the middle for 4wd. If you want to stay in 2wd, move it to the left for ATV’s and to the right for Rhino’s. Verify 2wd by jacking up the front wheels.
    Step 2- Reinstall the servo on the diff being careful not to move the slide gear from where you left it. Enjoy your ride and return to this troubleshooting page when you return to fix your problem.


    Problem 6My 4wd engages off and on without pressing the button.

    If your 4wd is going in and out without pressing the button, it is something that you can fix fairly easy. This is actually a common problem with the 12-15 models. Most of the time, the problem boils down to an intermittent connection. After dealing with this on several occasions, I have found a few things that will fix the issue.
    Step 1- Pull the plug off of your servo that’s on the front diff and put a dab of dielectric grease on the contacts and plug it back in. Ensure the connection is tight. Do the same thing to your plug coming from the 4wd switch. This usually fixes the problem. It also doesn’t hurt to apply dielectric grease to the 4wd relays while you’re at it. If you’re still having the problem, proceed to step 2.
    Step 2- If you’re still having problems after doing the previous step, remove the switch, clean the contacts inside and reassemble. You can see a video here on how to do so.

    Cleaning and Repairing the 4wd Push Button Switch
    https://www.youtube.com/watch?v=rCNTXsrnRaQ


    If you are still having problems after running these tests, you could possibly have a broken or shorted wire somewhere between the switch, relays, and servo. Give the wiring a good once over inspection and see if you can see any obvious problems. Let us know if we can help you further. 501-658-0219

    Here are two basic videos on how-to replace the servo motor inside the case.

    Replacing the Servo Motor Sealed Unit
    https://www.youtube.com/watch?v=CbgLENDH8Gs

    Replacing the Servo Motor Other Three Types
    https://www.youtube.com/watch?v=PUP3gC4VAeI

    Hopefully this helps somebody out.

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