My brother has a 06-07 500 4x4 auto-clutch. He has been having problems with the 4wd not going in when he flips the switch. It is intermittent, it may work 100 times and then not work once, work 5 times and then not work, really aggravating. He replaced the actuator for the 4wd and it seemed to help for a bit, all connections have been checked, he basically checked all the things that would normally cause an intermittent problem like he is having. He talked to the service manager at the dealership where he bought it and was told that they have been having problems out of that model of bike but didn't know the cause.

Anyone ever have this problem? Whats the fix?

You can e-mail me at: khaney01@windstream.net

Thanks in advance!

 

I've heard of this problem, and the multiple "fix's" for it. One you didn't mention was adjusting the actual cable on the actuator itself attached to the switch. I beleve some have found that it slips out of allignment w/the internal "workings".

It's a minor adjustment that makes all the differance

my 2¢

 

Are you referring to the diff-lock or the actuator that kicks it from 2wd to 4wd? The diff-lock works every time, the problem he is having is getting the front axle to pull at all. It may be all interconnected, I've never given it more than a passing glance.

 

Another fix I remember seeing in addition to the cable adjustment was doing something to the shaft that the worm gear rides on that engages the front diff. Had something to do with the worm or drive gear (which is plastic) slipping on a shaft and not engaging the front diff.