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Discussion Starter · #1 ·
I seen a thread on here about some fuel pump / over heating issues. Never really seen where there were any actual resolutions were offered. But i have a 2020 Kodiak 450 that i purchased last year and it had maybe 50 hrs on when it suddenly started just dying after riding for a bit. None of the Idiot lights came on, so i will assume that diagnostics cannot help with the issue. But i have a feeling this is an issue with the fuel pump overheating due to heat coming from motor considering that once I let it set for about 20 - 30 minute to (cool down) for a bit...it will fire back up and run fine. Yes I called a dealer where i requested to speak with a mechanic and asked if there were issues with this model having these issues. And did not surprise me of course i got the normal "Nope, nothing that we are experiencing" lol.
Now I am about 99% positive it is a fuel pump / heat issue due to upon turning key on at cold start, I can hear the steady sound/volume of the fuel pump charging. But when the quad has been ridden for awhile and dies / wont start. I then turn the key and can hear the fuel pump start to power/prime up then die down. But let it set for awhile....and the fuel pump with charge up normal & steady again and the quad once again runs fine. Again no idiot lights come on indicating overheating and nor when i crack the fuel cap open does any pressure come out. But I do sense that there is a some heat inside the tank.
Now I am kind of experienced with this type of issue, lol. Beings that i recently had this issue with a NEW 2016 polaris 450ho that i had purchased, that after one year it constantly ate fuel pump about every 6 months or so. Matter of fact that was why I got rid of the Polaris and bought the yamaha kodiak, lol. But with the Polaris, the actual temp light would come on indicating that the bike was overheating. Now after working repeatedly and very closely with my dealer whom has been in the business with his dad since he was a little kid. The issue with the Polaris was "appearing" to be that the tank vent had a plastic check valve/ball in it that would eventually stick closed from repeated heat from the motor. Thus it would build up pressure/heat and would cause the pressure regulator to puke fuel back into the tank and create a TON of air pressure. So much pressure that one time i took the cap off and it blew fuel out the tank over a foot into the air. But anyways, it was causing the bike would run lean and then overheat. But just like the Kodiak issue, lol. Let the Polaris cool down....and it would run again. But after so many times of that happening the fuel pump would just eventually crap out & need replaced. Thank GOD I purchased the polaris extended warranty & only had to pay $50 each time rather than the normal $750 that it would have cost me each time to get it replaced. But even with the warranty.... it became more about the inconvenience of it constantly happening and Polaris not ever offering any fixes/recalls/changes. Bottom line there is polaris KNEW they had an issue and wasnt ever going to fix the actual problem. And trust me, we taped the crap out of the tank with heat tape added heat shields etc. SO!!!, lol. Sadly this is where i am at "AGAIN" with the NEW yamaha 450. Yes i can purchase and easily replace the pump myself for right under $100.oo. and I actually did that already to end up having the same problem. So its NOT the pump....and has to be an excessive motor heat issue. Being able to easily change the pump aint the point...and Nor is it "FIXING" the actual issue.
So does ANYONE have ANY solution or suggestions to the problem? Cuz i have a feeling this is not just a random problem, nor that it is going to go away and I am sure that allot of others are experiencing the same issue. Thanks for all Input and/or suggestions.
 

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The problem with internet forums is that very seldom does anyone ever report back on what fixed their problem and it leaves everyone hanging out in the air. Not to mention those who come to them searching for a fix to a similar problem.

I would suggest that you get a volt meter and when it shuts down to start checking voltages on the main fuses and components. It may be a bad connection that is just fine while cold but opens up when things heat up, I have also seen the same problem as things cool off and loose a good connection.

I'm not anywhere near my manuals so that is the best that I can suggest that you check when the problem arises.


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19 Kodiak SE, Backcountry Blue, 27鈥 Reptiles, 1鈥 wheel spacers, 20* weights, shims, purple spring
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My 2019 Grizzly had a similar issue. After a 2 hour ride, and stopping by the lake鈥 it would not start. Dealer immediately identified it as the fur pump. There is a TSB for those fuel pumps. They replaced it for free. I haven鈥檛 shared the full news yet because I haven鈥檛 ridden it yet other than loading it on the trailer lol!

Yours sounds similar. However, does your die? Or just not start?
 

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Yamaha 2021 Kodiak 450eps se Yamaha 2020 WR250r
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This was a post about the fuel pump, I specifically had an issue with it blowing the fuse when powering on because of high amperage draw. Dont know if thats your issue or not but if its blowing FI fuses its worth looking into. You can check it with an amp meter. In my case I put the mechanics diagnosis and resolution on the reply linked.
 

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Discussion Starter · #5 ·
My 2019 Grizzly had a similar issue. After a 2 hour ride, and stopping by the lake鈥 it would not start. Dealer immediately identified it as the fur pump. There is a TSB for those fuel pumps. They replaced it for free. I haven鈥檛 shared the full news yet because I haven鈥檛 ridden it yet other than loading it on the trailer lol!

Yours sounds similar. However, does your die? Or just not start?
it will just start die like it is running out of gas. I will turn over....just wont start n run. Let it set for 30 minutes...and you are back in business
 

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My 2019 Grizzly had a similar issue. After a 2 hour ride, and stopping by the lake鈥 it would not start. Dealer immediately identified it as the fur pump. There is a TSB for those fuel pumps. They replaced it for free. I haven鈥檛 shared the full news yet because I haven鈥檛 ridden it yet other than loading it on the trailer lol!

Yours sounds similar. However, does your die? Or just not start?
Thanks for the heads up! I ll look into this for my own 2019 grizzly....
 
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19 Kodiak SE, Backcountry Blue, 27鈥 Reptiles, 1鈥 wheel spacers, 20* weights, shims, purple spring
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it will just start die like it is running out of gas. I will turn over....just wont start n run. Let it set for 30 minutes...and you are back in business
Still sounds like the fuel pump. A few members have found that adding a splash of cool gas helps. Might check with your dealer as to the years that they are replacing fuel pumps. Maybe it鈥檚 bigger than 2019
 

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Discussion Starter · #8 ·
i actually replaced the fuel pump and figured problem was solved. But actually..... it even happened with the new fuel pump. So thinking it is either heat from motor to the tank issue..... or maybe a voltage issue causing the pump to pull to much power causing it to overheat? Gonna try and call n talk to a dealer mechanic again today and see what i can come up with. I will share my findings.
 

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An over-voltage can cause something like cooking a battery but DC devices typically do not get caused to pull too much power. DC devices can get ruined by running above normal amps through them. For instance, a 30 amp relay that is energizing a device that is pulling more than 30 amps through the relay can ruin the relay or even melt the wiring if the wiring didn't support 30 amp draw.

Another item that is of concern, you mentioned replacing the fuel pump for under $100. That can only be a non-OEM fuel pump, new OEM fuel pumps are not even close to that price even with a huge discount. If you are going to take your Kodiak in for warranty work, best you get the proper OEM pump in there first.

What fuel are you running in your Kodiak?
 

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Discussion Starter · #10 ·
An over-voltage can cause something like cooking a battery but DC devices typically do not get caused to pull too much power. DC devices can get ruined by running above normal amps through them. For instance, a 30 amp relay that is energizing a device that is pulling more than 30 amps through the relay can ruin the relay or even melt the wiring if the wiring didn't support 30 amp draw.

Another item that is of concern, you mentioned replacing the fuel pump for under $100. That can only be a non-OEM fuel pump, new OEM fuel pumps are not even close to that price even with a huge discount. If you are going to take your Kodiak in for warranty work, best you get the proper OEM pump in there first.

What fuel are you running in your Kodiak?
Quad is past the 6 month warranty, so that option is out, lol.
Fuel pump is on a 10 amp fuse
And running the 87 octane.
 

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Same problem. 2021 Kodiak 450. 100 miles at dealer. They took fuel pump out and tested it. It is bad. However I鈥檓 not convinced it won鈥檛 happen again if overheating is causing it. 600$
 

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Discussion Starter · #12 ·
I refuse to pay the dealers $600.oo for a pump that can be EASILY replaced for about $90.oo. I purchased and replaced the OE Pump with the following
Fuel Pump W/ Regulator for Yamaha 2018-2021 Kodiak 450 Replace BB5-13907-02-00 / BB5-13907-03-00
Got it from www.eracingzone.com
Once i replaced the pump I thought i had it fixed.... Lol BUT!!!....It did the exact same thing after riding it about 5 r 6 times. I call and ask to talk with a mechanic at a Yamaha Dealer. But as you can imagine. They dont want to offer any over the phone assistance. Its always the same old "Bring Er In and we can diagnose it for ya". But i think as some are finding out $600 later..., lol. Just gonna happen again. All I want to find out and share with everyone is "The Permanent Fix"... NOT the "Temporary $600.oo Bandaid", lol
 

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The sad thing is that when you start experiencing problems that others haven't and you have tried a couple different solutions with nothing happening it may be time to head to the dealer and bite the bullet. That is unless you want to keep fiddling with it until you fix it by finding the actual problem or through attrition of replacing parts until you do with no idea of what part that you replaced fixed it.

Heat problems can point to a number of things and with the more electronics that these machines have the more heat related problems will rear their ugly heads. Since the ECM controls the fuel pump it just may be the problem, a fuse that opens up when it heats up can also be the problem among a dozen different things.

That is where you need to get a volt meter out and start checking things when it is running and when it dies and see if there is a difference somewhere. You can even hot wire the fuel pump and then turn on that switch when it won't start and see if that fixes the problem or if it still won't start. At least that will point you elsewhere besides the fuel pump.
 

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Also if you take it to a dealer find out what kind of warranty they offer on their work, parts + labor or just parts. Along with what they will do for you if what they do doesn't fix the problem
 
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2021 Kodiak 700 Stock 2019 Kodiak 450 1.5鈥 lift on 27s 2018 Kodiak 450 Stock
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This was a post about the fuel pump, I specifically had an issue with it blowing the fuse when powering on because of high amperage draw. Dont know if thats your issue or not but if its blowing FI fuses its worth looking into. You can check it with an amp meter. In my case I put the mechanics diagnosis and resolution on the reply linked.
I was looking for my own thread and you already posted it. Thank you! On the 450s, changing the fuel pump is really easy. When mine went out, I had never done one before but it鈥檚 all literally right there for you to get to. $350 got me the whole assembly and I had it switched in not long at all. Half hour or less. I don鈥檛 know if mine was overheating at all but if anyone needs it changed outside of warranty, don鈥檛 be afraid to tackle it yourself!
 

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You might want to check the relays too. Yamaha replaced my starter relay and the relay right off of the "power Strg Cont. Unit Assy. along with the pump. I am not sure which relay that is.


.
I refuse to pay the dealers $600.oo for a pump that can be EASILY replaced for about $90.oo. I purchased and replaced the OE Pump with the following
Fuel Pump W/ Regulator for Yamaha 2018-2021 Kodiak 450 Replace BB5-13907-02-00 / BB5-13907-03-00
Got it from www.eracingzone.com
Once i replaced the pump I thought i had it fixed.... Lol BUT!!!....It did the exact same thing after riding it about 5 r 6 times. I call and ask to talk with a mechanic at a Yamaha Dealer. But as you can imagine. They dont want to offer any over the phone assistance. Its always the same old "Bring Er In and we can diagnose it for ya". But i think as some are finding out $600 later..., lol. Just gonna happen again. All I want to find out and share with everyone is "The Permanent Fix"... NOT the "Temporary $600.oo Bandaid", lol
It is possible it could have been a covered warranty issue due to a faulty part(s) even if the machine is out of warranty.
 
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