I ran over a large stick over the weekend. The stick pulled some wires loose. I discovered this after getting stuck and when I pushed the 4 wheel drive button the front wheels did nothing. The wires are attached to the frame on the left side right behind the shock. It pulled out 4 wires that seemed to go back into place without any problems. As I was putting the wires into place I just happened to put my hand on the unit that engages the 4 wheel drive system. It was very warm if not hot to the touch. I unhooked the battery to avoid burning it up but I now think it's fried. Any suggestions would be helpful. The quad was cold when I tried to hook the wires back up so the heat was generated in just a few minutes. Or maybe it was hot because the wires were hooked up wrong. Not really sure.

 

Ok, now did it just come unplugged at the connector, or did the wires themselves come out of the connector? If you pulled the wires out of the connector and just pushed them back in it's possible you plugged them in the wrong orientation. It's possible your 4wd motor is fried, it's possible the selector relay is fried, or your switch is bad, or everythings fine and u just got ur wires crossed. If when you press in the button do you hear a click? If you hear no click then it's probably a relay or crossed wires. Got a multi meter? The 2wd/4wd selecting button should read 0O from Orange to Black wire in 2wd and 0O from Orange to Blue wire in 4wd. I can't scan photos, you basically have two options. Take it to a shop, wait and pay out the ****. Or goto a shop or online and buy a repair manual-$60. I ahve the factory suzuki and it has all the info you would need to fix this. Without knowing exactly what wires came out where I really can't help you. Can you take a photo of what became disconnected and put it in your profile or pm me and we'll make email arrangements. But you'd still be best served by buying the service manual anyway. You still could have something burnt up, but in the meantime you need to park the bike till you address this issue before it cascades into other problems.

 

MeYHymN,
Thanks for replying! The wires pulled out of the connectors. I went to a local Suzuki dealer to see how the wires go. As it turns out I had a green and red wire reversed. Once hooked up correctly the system is working. I can here it engage and disengage properly now. I may have shortened the life of the 4 wheel drive motor since I got it as hot as it was.
How does your Harbor Freight winch work? I was thinking about getting one.