Help 05 grizzly rear axles keep popping out

[coolio]

05 stock grizzly with 26 in tires with 550 mi on it. I had 2 passengers on it crawling slowly out my rough camp road when i got stuck. Then i discovered both rear axles had popped out of the rear diff and then it filled with water. It was basicly a new machine with 400 mi on it. Called the dealer and they told me that they do that sometimes and to spread out the lockrings when i put it back together which i did and to take the 26 in tires off which I did not. Then the other day when pulling on a stuck atv and spinning all 4 tires in low range the right axle popped out. WTF ??? I thought these things were bulletproof. Nothing is bent or broken that I can see. I own and have owned many Yamaha sleds and atv's and have never seen anything like it. It's a very cheesy setup and I can't believe that 26 in tires cause it when many people run bigger tires than that. Has this happened to anyone else? Any input would be helpful as I'm ready to sell this POS. Oh and did I mention the hitch broke off the first day I pulled my woods trailer with it? I'm pretty dissapointed with the ruggedness of this thing!
________
North American Racing Team

 

[pat the rat]

where do i start,i now own a new grizz 700 but had a 2003 660 prior to this one,in fact all my hunting group ride 660's,my 03 popped the axles at around 3000 miles riding two up in really rough terrain,called the dealer and he told me exactly the same,buy a new ring and spread it a tad then install,did that and it cured my problem,rode it to 8500 miles without a problem,last week my buds grizz popped both at the same time,he had bought new rings before hunting started just in case,fixed it at the camp and its fine now,my brothers did the same,i think they all do it and most of the time,its two up riding that is the cause,there is a kit you can buy,its like a bolt that bolts both axles together so its impossible for them to pop out,dont give up on youre bike,they are tough,except for that flaw,the bolts that hold the hitch are meant to break before the frame bends,simple fix,install the 2'' receiver hitch kit,the new 700 imo is a much better bike cuz of the new features like efi and power sterring but take that out and the 660 is almost equal,good luck,

 

[coolio]

Does anyone know where this kit is availabe to bolt the rear axles together? Both of my axles popped out again and now they are stripped and I'll have to replace both axles I guess. All i did was put a big buck on the rack and take it through a chopping. What a pos!!!!!!!!!!!
________
No2 Vaporizer Review

 

[MrSled]

Take it back to the dealer... Yamaha needs to know.

 

[coolio]

I talked to my long term dealer and they said that they had not had problems with the axles popping out on stock ones and had heard about them popping out on modified ones. My machine is out of warranty a long ways but it's stock except for 26 in. mudlites. When I took the inner cv joints apart one of the rings that holds the cage in was bent and all loose in the boot. I don't understand why it pulls itself apart. It is like the axles are too short. I opened the diff, cleaned it, and I'm waiting on parts now. I think I should sell it and buy a honda. It has a solid rear axle at least. I'm suprised that there hasn't been much help here.
________
Dating Advice Forums

 

[MrSled]

you may have to go to different axles.

 

[Camo7]

I've seen this axle problem a few times on friends 660's. All of the modified in some way with pipes and/or tires. my 660 has 27"589 M/S tires on it. I don't abuse it because I hate fixing broken bikes. No problems so far. If your axles pop out while carrying a deer out on a rough road, how much did the deer weigh? I think Yamaha limits the rear rack at a bit less than 200lbs. 2 riders at 225 lbs plus a bigger set of tires equals a lot of extra torque on the drive train that the unit wasn't designed for. I''ve owned Yamaha's in one form or another for 30 years. Rule of thumb, leave them stock and don't abuse them and they'll last for ever. Modify them and some models will take it, some will break. This rear axle popping out problem seems to be a weak spot on the 660's. If your running bigger tires and "Root'n on it", fix the week spot before it leaves you stranded. Simple fix!