HELLO I HAVE AN AC 300 2000, TODAY ON MY WAY OUT OF THE WOODS I NOTICED THAT THE FRONT DIFF WAS MAKING A CLICKING SOUND FROM TIME TO TIME AND THE 4 WHEEL DRIVE SEEMED TO BE KICKING IN AND OUT ALSO THE ACTIVATION LEVER ON THE DIFF SEEMS TO MOVE UP AND DOWN EASIER THAN IT USED TO ANY IDEAS WHAT IS GOING WITH THIS THING.

 

If the 4 wheel drive is cable operated,maybe a broken cable and it' not holding the 4wheel drive out, not familiar with the bike ,so it' just a guess.
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07 650 trv stock for now

 

sounds like your engagement fork is wearing out, or the rod/lever on the actual diff needs adjusted. SHouldnt be much to it at all. pretty simple stuff in the diff. Pull up a parts diagram, and check out the assembly.

 

I THINK THE ADJ. PART IS THE RIGHT THING HERE IS WHY I THINK SO . THE OTHER DAY I WAS READING ABOUT MOVING THE ENGAGEMENT LEVER FARTHER SO WITHOUT UNHOOKING THE CABLE I USED A SCREWDRIVER AND PRIED IT DOWN ABOUT A HALF INCH THERES STILL ABOUT A QUARTER OF AND INCH LEFT AT THE ACTIVATION HANDLE. I THINK WHAT HAS HAPPENED IS WHEN I MOVED THE LEVER THE CABLE IS NOT HOLDING ENOUGH TENSION TO KEEP THE LEVER DOWN THAT EXTRA HALF INCH. THOUGHT ABOUT USING A BUNGEE CORD FOR THE TIME BEING TO HOLD TENSION UNTIL I CAN DO A PERMANENT HOOKUP. WHAT DO YOU HUYS THINK ABOUT THIS IDEA. THANKS FOR ALL YOUR HELP

 

Yup, youre on the right track. I dont remember exactly how to do the mod, but I do know it icludes engaging the 4x4 lever further past the sock position. It seems like people were bending the rod somehow to get it to do it and/or welding a extension to it.