About 2 months ago the 4wd on my 750 just quit working without warning. I tested the switch and all connectors and found no problems so I decided to take it to the dealership. Needless to say, two months later I still dont have 4wd. They have replaced both modules(EBC and 4wd) and what they said was a wheel speed sensor. Now they are saying that Kawi Tech says they should replace the whole wiring harness on the thing which doesnt sound right to me but oh well. My question is this; I have a highlifter CDI box. Is this reusable or should I just buy a new one? If so should I cut it out before I take it in or just let them do it? The dealership is aware that it is there and so far have not indicated that this voids the warranty. Let me also say that the dealership has been more than helpful and it is in no way their fault it has taken so long to get it fixed. My frustration is with Kawasaki

 

Just snip the wires close as possible to wire harness or de-solder & save your module.
Are you getting power to your Actuator & 4 X 4 switch on handlebar & ruled out a bad fuse or fuse holder?[img]i/expressions/face-icon-small-confused.gif[/img]

 

yep. checked all fuses and power to the actuator myself. we even checked each individual wire for breaks in connection and none were found. Thats why i'm confused about needing a whole new harness. Has anyone else ever heard of this? I called several dealerships and they said that they have never heard of this problem.

 

What About at the Front Differential? Lines could have got yanked off?[img]i/expressions/face-icon-small-shocked.gif[/img]

 

Have your dealer try a new ignitor. You will need to first remove the rev box you spliced in. I am willing to bet you that this will 100% correct the problem. Kawasaki has had some issues with connectors inside the wiring harness corroding. This will cause a low voltage situation on the actuators. I just went through the smae situation and it was the ignitor box. I can only guess that the rev box caused a short of some type. let us know.

 

We were thinking the same exact thing(we were doing some of our own diagnoses using repair manual) but the dealership insists this thing needs a wiring harness.I'm wondering if in fact there is a short being created because now my reverse override doesnt work either. Did you replace your rev box or leave it unhooked. I dont know if I could live without it now.

 

Have your dealer remove the cdi rev box and try a ignitor from a new unit. It will correct all your problems. We recommended that the customer not run the rev box in the future if he wants any warranty claims. Kawasaki will probably not cover the harness if they see the splices from the rev box. If the ignitor is the issue they will replace that under warranty, if you still have any.

 

Where is ignitor located? My buddy has a brute also. We'll just swap them and see if that fixes it.