My 95 Xplorer 400 goes into 4 wheel drive in reverse, but not in forward. Anybody else have this problem? Any solutions or where to start looking? Also, the light doesn't come on in the switch that shows 4 or 2 wheel. Thanks!

 

Had a similar situation on my 97 explorer last spring and I wrote this for the checks I did.....

checked continuity in AWD switch = O.K., Checked continuity in AWD light bulb = O.K., Checked voltage to transmission shifter switch = O.K., checked transmission shifter switch voltage in neutral =O.K., checked transmission shifter switch voltage in forward = NO VOLTAGE (PROBLEM FOUND)., checked transmission shifter switch voltage in reverse = NO VOLTAGE (PROBLEM FOUND)... Noticed that neutral light on light Bezel stays lit...(PROBLEM CONFIRMED)...The transmission shifter switch is shot..... Took shift linkage apart, disconnected the transmission switch wiring from board under light, removed the shifter mechanism from bike and put in vise, took apart the shifter mechanism slowly ( unit is under spring pressure) and voila.. a switch with a broken toggle.. its stuck in neutral all the time therefore power doesn't go to the AWD...Well, got new switch, $130.00 + tax canadian (ouch)., anyway, installed it into shift selector assembly after having cleaned all parts of assembly and adding new oil, mounted assembly into bike, wired to board, turn key on,

neutral light = o.k.,
shift in reverse = O.K.,
press AWD button & override button while in reverse = O.K.,

shift into forward with AWD button engaged = ....PROBLEM _ NO LITE

push a little on shifter AWD lite goes on., disconnected shift link rods from transmission to see if mis-adjusted arms, no change therefore problem in shifter assembly... Took shift assembly out of bike again, took apart, noticed that the detent bullets that hold the shift sliders are very worn, thereby allowing the shifter handle to be out of its centered position, and not holding the shift selector switch at the right spot to allow power to flow through to my AWD switch....will have to go to dealer again for detent bullets, springs, and might as well get a new cup bearing while there.... I guess that with the constant shifting from forward to reverse and back I do so often with the bike due to the blower in winter and with the mower in summer for the last 6 or 7 yrs is finally catching up.....


and I also wrote this a while back for someone who had a similar problem with a 95 sportsman , but here you go....

I don't know if the wiring is the same color or have the wiring diagram for your machine. It may be similar enough to help you.

With the shifter :

In neutral : power from red/white wire goes to trans switch to green/white wire to neutral indicator lite to ground.

In reverse: power from red/white wire goes to trans switch to purple wire to reverse lite to ground. The purple wire splits and goes to the over ride switch -> DON'T press over ride button and power goes through to green wire to speed limiter, slowing you. DO press over ride button and power goes through to grey/white wire to AWD switch. DON'T press AWD button and you have fast reverse in two wheel drive. DO press AWD button and power goes through to gray wire which splits and feeds the AWD lite to ground and the AWD coils to ground. fast 4x4 in reverse.

In forward: power from red/white wire goes to trans switch to grey/white wire to AWD switch. DON'T press AWD button and you have fast forward in two wheel drive. DO press AWD button and power goes through to gray wire which splits and feeds the AWD lite to ground and the AWD coils to ground. fast 4x4 in forward.

So i would say:
1) If in forward, you should still have AWD and an AWD lite, if not, I would say you have either a disconnected or shorted red/white wire to trans switch, damaged trans switch, disconnected or shorted grey/white wire to AWD switch, damaged AWD switch, or disconnected grey wire from AWD switch were it connects at terminal board. However, if its the trans switch then you should have no neutral or reverse lites in those positions...

2) If in reverse, you should have a reverse lite, if not, you have either a disconnected or shorted red/white wire to trans switch, damaged trans switch, a shorted purple wire from trans switch to terminal board, or a disconnected purple wire from trans switch at terminal board, . If you have a reverse light, then you have a disconnected purple wire at terminal board from over ride switch, resulting in no power to grey/white wire therefore no AWD and no hub engagement.

Hope this helps.....

.........Honcho.....

 

Thanks Honcho. Was messing with (AWD Switch) tonight. Mulitmeter to grey and grey w/white stripe. Nothing. Put it in H. Small little sparks. Moved to L. small little sparks and AWD light lit up and coils could be heard engaging. Noticed shifter assy was loose, so I tighted it up. I thought cool! bad contacts causing ground problem. Cleaned contacts on circuit board one at a time, and guess what? Back to square 1! I'm thinking the AWD switch is the culprit. I'll know more tommorrow......

 

Ok, it was the microswitch in the shifter. Put the damn thing in backwards first time. Old toggle is 4 wires in a row, New toggle is 4 wires in a square. If you install so purple wire is on top and closest to engine, you won't have to do it again! Switch has been upgraded form plastic toggle to metal. Should be alot stronger. Thanks for the input!

 

How much was the parts to fix the atv?

 

If it is the switch, according to partsland : $79.99 U.S.

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Be careful taking the selector apart, its spring loaded and you could strip the bolts that hold it together or break your switch if its not already broke...

.....Honcho....