Has anyone had any problems with the diff locks?? I ride with an 05 500 and an 06 400 and both of them have been having issues with the diff locks not engaging. They'll be in one mud hole and it'll work fine and then the next 5 it won't work. They are engaging it correctly and theres never any noise like gears not meshing, so everyone is a little baffled.

Anyone else have some issues with this? Thanks in advance

 

I've had my 06 400 for a few months now. I've only used the diff lock 3 times, but each time it worked wonderfully! Be sure that your buddies realize that it takes a few rotations for the tires to lock in. It's kinda of difficult because you don't anticipate getting stuck very often. My recommendation would be that before you get good-'n-stuck, lock it in.

One time when I used it, I was stuck in a creek crossing. To get out of the creek you had to climb a short, but fairly steep, step. Problem was that it had rained a lot in the area for a few days, so instead of getting a little bit of steam going up to that crossing, I was going slow. I got to the step and 4WD just wasn't cutting it. So I locked it in, backed off a tad, and then crawled right up the step with no problem. Tell your buddies to watch the display as well; it will say "LOCK" when it's fully engaged.

Hope that helps!

 

You probably need to adjust the cable. There is a sheath a little down from the lever that you need to pull back, then you can tighten it. It should engage around a half turn of the lever. I did it to mine, and it works great now. You may also have to turn the handlebars back and forth to get it to engage. Also, leave it in 2wd while checking this. When you flip the lever, you will hear the 4wd actuator when it engages and disengages.

 

mine i just have to wiggle the handlebars a little and it engages.

 

check your left front axle where it goes into the front diff mine slipped out just a little bit and the diff lock gear wasn't connecting with the axle when you flipped the lever so it wasn't engaging. all i had to do was push the axle back in and it's been working fine ever since that was about 800 miles ago you might want to replace the lock ring on the axle if this is the problem it's not hard to replace and is what keeps the axle in the diff hope this helps

 

Thanks for the replies. I'll pass this info on to the boys next ride and hopefully we'll get it figured out.