I just test drove a 2003 foreman s. I noticed that the 2 - 4 wheel drive button would only work when the quad was below 3 mph. That was to switch it into 2 or 4 wheel drive. I had a 2004 rancher at and you could shift it at any speed. Is that the way the older foremans are suppose to do? Or are you suppose to be able to shift it at any speed. Thanks

 

I HAVE A 2004 450 FOREMAN 4X4 & I HAVE TO BE BELOW 6 MPH TO SHIFT IT INTO 4 WHEEL DRIVE. ITS A SAFETY ISSUE......

 

I have an 03 es, and i can shift when ever i want. But the switching wont take place until the load comes off. If im in 4wd, and have the power on, and use my left hand to switch to 2wd..it wont complete the action, until i either lighten up on the throttle or the load equalizes. same with going into 4wd...do it anytime you want, but the clutch wont engage and the light wont light,until the load is equal on the front to back.

 

YOUR CORRECT . THATS WHY I SAID THAT IT WON'T GO INTO 4 WHEEL DRIVE UNTIL I'M UNDER 6 MPH. I CAN SHIFT IT ANY TIME THAT I WANT BUT IT DOESN'T INGAGE UNTIL I'M LESS THAN 6 MPH. I'VE TRIED IT AT ALL SPEEDS. THANKS !!!

 

But it will also engage and disengage at any speed(all the way up to top speed). Ive been going 45 mph and itll switch on command...as long as the load to the front shaft is equal to the load on the rear shaft. Usually all it takes is a momentary letup on the throttle, and itll engage seamlessly.
Yours might be low on front diff fluid, if it doesnt seem to shift until 6 mph.

 

NO, ITS NOT LOW ON FLUID. I WILL TRY IT TOMORROW TO SEE IF MY BIKE WILL DO THE SAME AS YOURS. I KNOW THAT I'VE TRIED IT AT 25 MPH & IT WOULDN'T INGAGE UNTIL I SLOWED DOWN UNTIL 6 MPH. THANKS !!!

 

i usually just tap the brake and it always engages.

 

THATS COOL! EACH BIKE MIGHT ACK A LITTLE DIFFERENT.

 

Well I still have the problem. I should be able to shift in and out at any speed. I tried tapping the front brake and it worked like a charm. I was going about 25 mph and put it 4 wheel drive and then I put it back in 2 wheel drive and the 4 wheel drive light was still on as soon as I tapped the front brake it went off. I also turned the bike kind of rapididly and it went off as well. What is the problem with it? I have an extended warranty until nv of 06 will they fix the problem for free? Thanks for any inputs.

 

That sounds pretty normal. I doubt they will do anything at the dealership...it says to not do this in the owners manual. Although its for saftey, not because it wont. It sure wont hurt to ask, they wont null whats left of the warentee over that.
Are both front tires the same size and same air pressure? If one is a bigger diameter than the other, that might be the resistance the torque sensing diff is feeling, and if theres any load on the gears (either direction...engine driving the wheels or wheels driving the motor), it wont slip in or out.
Many times,on the foreman, i have it in 2wd, and i reach over with the left hand and flick it into 4wd, while the power is on,just before arriving in a slippery area. Then all i have to do, is ease up on the throttle..and i have 4wd.(kind of like how a splitter on a big truck works, its all prepared to move, it just needs a bit of a reduction in load to do it) If yours needs a tap of the front brake or a handlebar move, maybe thats what it takes.
Have you tried changing the front diff fluid...and use a synthetic? Thats the only difference mine has over stock.