04 rhino 660 sputters at 35mph - Yamaha Rhino Forums - Yamaha UTV Forum
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post #1 of 10 (permalink) Old 09-22-2010, 11:56 AM Thread Starter
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04 rhino 660 sputters at 35mph

Hi this is my first post. My 04 rhino runs perfect until it gets to 35mph then it starts to sputter and wont go any faster. it has a clean air filer and a new fuel filter. any ideas?
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post #2 of 10 (permalink) Old 09-23-2010, 09:43 AM
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It is the rev limiter, it is set to kick in at about 40mph ish but I am willing to bet your belt is pretty worn which will cost a few mph off the top. Dynatec has a great cdi box that removes the limiter and would add about 8mph. If you install the cdi box you would be wise to also install a machined sheave to lower the rpm up top- The 660 doesnt like high revs for long

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post #3 of 10 (permalink) Old 11-19-2010, 01:01 PM
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I am having the exact same problemmotor sputters at 34 to 36 mph.

We have done a ton of things trying to find the issue, in some ways it seems like it is hitting the rev limiter.
What we did:
Cleaned the sheave
Replaced the drive belt
Cleaned the Carb (4 times)
Cleaned out or replaced all fuel hoses
Cleaned and changed air filters
It has an after market CDI - tried putting stock back in (no work, problem at same point)
swapped fuel pump with someone else
changed oil and filter

ANYONE have a new suggestion?
I have it at a Yami Dealer and the answer given to me was "they are only made to go 35 mph so what is my problem"
It went 45 before I did the above maintenence
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post #4 of 10 (permalink) Old 11-19-2010, 02:51 PM
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post #5 of 10 (permalink) Old 12-28-2010, 08:12 PM
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Angry Same thing happening!!!!

I have a 686 with dual exhaust and a stock carb, all of a sudden the thing starts sputtering and a small pop through the air cleaner. I have also been through the carb four times, checked valves and changed plug, fuel filter installed new battery thinking maybe voltage on old battery was affecting cdi and still cant get rid of this very quick miss and light pop in the carb. I am thinking of buying a Mikunio 45mm carb but want to be sure this is the problem. It sure seems like fuel issue but have no idea at this point. I am going to doa leak down test and make sure its not low compression or a valve issue but at times it will get through the sputters and run strong for 10 seconds otr so then it will return.

Any ideas????? I am supposed to be going to Dumont for New Years and this issue is going to make me cancel if I cant figure it out.

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post #6 of 10 (permalink) Old 12-29-2010, 03:49 PM
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If you figure out what is causing it please let me know.

I just addedd a High Flow fuel pump and it gave me a little more rev before it happened.
I have narrowed my problem down to a certain point of throttle. I can hold it almost wide open and I am ok until I hit 39 to 40, if I push down a notch more it pops and slows down.
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post #7 of 10 (permalink) Old 01-01-2011, 06:16 PM
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As Dirtysidedown stated it's hitting the rev limiter, and your belt is most likely worn out as well in all your posted cases. Replace the belt and cdi and you will be amazed at what happens. I have seen alot of after market cdi fail as well and the first indication is you loose the higher rev limit or they just start to misfire.
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post #8 of 10 (permalink) Old 01-03-2011, 10:27 PM
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I was having a simular issue heard of a friend changing his stator so i tried that. It solved my problem.
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post #9 of 10 (permalink) Old 01-05-2011, 12:40 AM
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Figured out my high rpm miss!!!!

After 5 times through the carb, new sheave, plug, chasing grounds and looking for shorts it turned out to be my reverse rev limiter! I noticed my reverse light flickered on while it was missing and I pulled the green wire apart right where all the wires come up on the passenger side kind of by the carb and crimped the female connector a bit and it ran perfect. Sucks I figured it out on Sunday after driving all over dumont for three days with a bad miss at anything over 50% throttle but that was the issue.

Just thought I would post it for future reference if anyones Rhino does the same type of thing.
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post #10 of 10 (permalink) Old 01-21-2011, 11:08 PM
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My problem is finally corrected. Took it to John in Stanton and he found the problem.
Turns out the guy we bought it from last year had tried to fix his power problem by re-jetting the carb and the CDI.

Once I cleaned the sheave and put a new belt on, it fixed the power problem but created a new one. The guy had a 160 jet in there and when we get totally on it the carb was flooding, not starving for fuel like the Yamaha dealer said when he had it.

The solution was to reduce the jet size. Now with a clean sheave, new bely and stock jets, it jumps to 50mph quick.

Simple fix, wish we would have found it sooner.
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