My next local XC race is coming up on Sunday, Oct 24th...the problem is that my 2wd/4wd actuator is currently removed (its at the dealership) and I'm now awaiting a replacement part that is on backorder (not expected to arrive until end of this month or early next month). So unless I find a way to fabricate a simple way to lock my front diff into either 2wd or 4wd, I will not be able to race on the 24th.

With the 2wd/4wd actuator removed, I can see a round collar that slides back and forth over a shaft by the 2wd/4wd actuator motor so that it will engage or disengage 4wd. If it don't rain anytime soon, I probably won't actually need 4wd in this upcoming race, so I would be happy to find a way to insert something that would hold the collar forward (or backward) on the shaft so that it remains in 2wd (or 4wd) the entire race. I don't want to race as it sits right now b/c the collar is totally free to slide back and forth (which would engage/disengage 4wd at random times).

Does anyone have any suggestions for me?

 

Mikeyboyesqu--wish i was there to see it---on my last jeep wrangler the actuator was vacuum operated and pulled a collar with a fork to connect a front axle which in turn made the front differential operative ---this actuator also sucked and jeep later eliminated it and left the front end locked in all the time saying the energy and gas mileage lost from having front end locked in was so negligible that it didnt matter----but on the jeep, you still have the transfer case lever to switch the transfer case from 2 wd to 4wd---our Kawi's dont give us that option---if i figure correctly the Kawi's are always in 4 wd and the actuator connects and disconnects the front end??? This is such a pis poor setup and I keep looking at a warn front end disconnect with a push pull button for yamahas that i'll bet could be made to work---I would gladly trade the electro unit for a cable operated unit-- On my jeep, I welded a small bead on both sides of the collar on the axles and locked it in permanently---can you possibly get a hose clamp around the axle to either hold your collar in or out of 4wd ?? Seems if you could get a small hose clamp on either side of your collar you would have a temp fix.

 

OleManMoses,
Thank you for the hose clamp suggestion... not sure how much room I have to work with inside the front diff., but if I can get a hose clamp in there to hold the collar in place, I might just give it a try.

Happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]

 

Mikey i would'nt ride the bike without a actuator or the slide block might move and cause the front diff to engage at high speed, I would atleast put the old one back on. You need to call mike penland i bet he has a used one somewhere laying around. his phone # is on nyrocks's site

 

Thanx for the suggestion. I wonder if I removed the drive shaft, then would it be ok to race it without the actuator installed? It seems to me that without the drive shaft, it should not put much pressure on the diff parts even if it engages and disengages randomly while riding it (keep in mind that I'm going to replace the collar soon...its one of the parts on backorder). So what do you think?

Happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]

 

On my chevy pick up, a 92. The front end is engauged with a piece of crap thermal actuator. They are Junk in really cold weather, but back to the topic, you can stick a dowel pin in there far enough to move the shaft inside the front diff and you have 4x4 So if you could get some one to fabricate you a long enough dowel pin and threads on the end of it you can screw it into your diff. case.

I have no idea how your front end looks on your quad that is just the way you could do it on a pick up front end.