2004 - 2006 Grizzly Reverse Limiter Override



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This or any modification to your ATV, should be performed ONLY at your own risk.  DISCLAIMER

Before attempting any work, read the entire article to help eliminate surprizes.

Purpose of this modification:
To remove the RPM limiter when operating in Reverse.

Results to expect after successful competion of this modification:
The engine sputtering will no longer occur while in reverse. In mud and snow, the added wheel-speed allows much better control if you become stuck.

Negative side effects of this modification:
The reverse indicator will no not function. This is an acceptable trade-off for most riders.

Skill level:
Basic electrical

Tools required:
Basic handtools

Parts or materials required:
SPST switch, wire, solderless terminals

Approximate or estimated cost of mod:
$10

1

A side affect of this mod is that the Reverse Indicator LED on your digital display unit will no longer work. Most consider this to be an acceptable trade-off.

Remove the left side panel and locate the “Green w/ White stripe” wire. It should have a clear vinyl insulated bullet style connector as shown in the photo at the right.

NOTE: There is also a “White w/ Green stripe” wire in that location. It is NOT the correct wire for this mod. Locate BOTH of these wires and look closely to make sure you have the right one. The wrong wire has no connector. You do NOT need to CUT any OEM wires for this mod.











2

Once you have located the “Green w/ White stripe” wire and its connector, unplug it. Now a jumper (below right) needs to be fabricated that will plug into both of those connectors. One male and one female bullet style. The Jumper needs to be able to plug into the “Green w/ White stripe” wire so it can be grounded. The jumper is shown below on the right. Notice the “extra” new wire with no terminal on the end. It will go to ground in the next step.















At this point, you have three options for control of this mod.

1. You can choose to use the original Yamaha “Diff-Lock Override” pushbutton for on command “ONLY”. This is the most popular method for the 04 and later Grizz because you already have a functioning button in the right place, at your left thumb.

2. You can choose to hardwire the jumper to ground. This will make the override non-switched, so it will be constantly in the override mode. This is the more popular option, because you never have to think about it again and it does not require you to loosen your grip on the bars to find a button to push in a sticky situation.

3. You can also choose to use a separate pushbutton or toggle switch to ground the wire, on command “ONLY”. This is the less popular method because you have to alter your grip on the bars to push a button. One very good reason to choose this option is if other riders are likely to ride your Grizzly. It is dangerous to operate the Grizzly in reverse at high speed.



Jumper

If you choose to make the override a constant (hardwired) condition, just locate a good place to ground the new wire and your done.

To use any kind of third party pushbutton or switch to control this mod, simply route the “new” overrirde wire to to either terminal of your switch and the remaining switch terminal to ground. When the switch is in the on (closed) condition, the override will be engaged.









location

If you choose to use the original Yamaha “Diff-Lock Override” pushbutton to control this mod, you will need to remove the front rack and plastic hood to gain access to one more wire.

Once you have access under the front hood area, you should see several wires and connectors. It only looks scary.

Locate the “Light Green / Brown dots” wire. (There seems to be 2 different variations of this wire, so the brown dots may or may not be visible on yours.)

Verify the correct wire by the photo on the right. The connectors are located just below and in front of the digital speedometer cluster. The connector is “White” and contains 3 wires as shown. It should be the only one in that area with a “Light Green / Brown dots” wire.

Once you have located and verified the correct wire, just tap the override (new) wire to the “Light Green / Brown dots” wire. To do this, a wire tap such as the one shown in the photo below is the fastest and easiest method.

This method will not alter or interfere with the original function of the Diff-Lock Override Button.

Be sure to test your mod before assembling everything. Reverse should no longer have a speed limiter, as long as the override button is pressed and held in.







diagramTap
















NOTES:

If you prefer to use a momentary pushbutton control, be sure to place it in a location that can be easily reached from the hand grip.

If you prefer to use a toggle switch control, be sure it cannot inadvertently be switched. An indicating type switch would be a good choice.



TIP:

While you are accessing the electrical wiring connectors of your Grizzly, it would be a great time to apply dielectric grease to any and all electrical connectors you can get to. Even if you don't use your Grizzly in water or mud, it can help to prevent corrosion in the terminals.