Hayashi
Thanks for the info.I will check what your telling me.For now i applied direct battery voltage to the actuator to transfer her into 4wd for the time being and left the plug disconnected so she won't come out of 4wd.I have a dg3 module but i don't believe thats the problem.I switched the controller module under the seat with another prairie of the same year and it still said it was in 4wd but was not engaging.My buddy thinks it's the actuator but i'm skeptical because it moves with applied voltage.I don't know, but right now i'm happy i have 4wd.Next month were heading down to Hatfield Mcoy in West Virginia.So if i dont fix her by then at least i have 4wd and know it's engaged and not coming out.Thanks for the help.Your the best

 

Your DG3 might have done some damage to the 4WD activation cirucuitry of the igniter - not producing 4.8 volts to the control unit. If you spliced into the pink wire to the igniter, I am almost certain. The DG3 module somehow fed in more than 5 volts to the igniter to advance the ignition timing through the pink wire (coming from speedo sensor). Anything higher than 5 volts to the pink wire would damage the 4WD circuitry of the igniter.
Good Luck.

 

Birdbath
I was under impression 4-Wheeler has to be moving to go into 4-Wheel drive?. Does it not go into 4WD while moving and or pulling yellow front 4WD lock lever?

 

Hayashi, The dg3 was installed a year or so ago.I will check what you told me when i have some time.I hope that didn't cause me problems.I totally went against my gut instinct and put that on.I know from past experience that most aftermarket stuff will cause you problems down the road and i was hesitant to install it.I heat shrunk and soldered everything and it's been fine .Thanks for the advice.Also i mentioned to you i swapped out the module with the green and black wires you were telling me to check with another prairie and still no 4wd.What do you think of that?Isn't that where the feed for the engagement of the 4wd actuator comes from. Thanks

 

tuffenuff, the wheeler has to be moving to go into 4wd.I know it will not engage at higher speeds.Pulling the yellow lever will do nothing unless 4wd is engaged.It will make your steering feel like it is in differential lock if you pull the yellow lever regardless if your in 2wd or 4wd.The front actuator has to engage in order to connect the front differential to the shaft coming out of the motor which is always spinning.I wish kawasaki would have made this machine with mechanical engagement of the 4wd rather than electrical,..But then they wouldn't make no money cause it would never break.At least the differential lock is mechanical. Later

 

I'm not too clear which "module" you swapped out and what you were looking for. I need to know:
1). What happened (2/4wd) when you installed your igniter on the other Prairie?
2). What happened (2/4wd) when you installed the other P's igniter on your bike?
3). Any funny thing with speedometer reading (accuracy)?
Good Luck.

 

Under the seat you have what i call modules.You have a large module which is your igniter.Then you have a smaller one which is the actuator controller.The actuator controller is the one i swapped with another prairie and still no actuation.Next time i see my friend i will swap the igniters if you think that might work.I didn't do that.This thing had me thinking in circles.Sorry for the confusion!

 

Exactly.
You need to swap out the igniter, the big one with 3 connectors. Igniter supplies 5VDC to the control unit. If there is no 5VDC coming out from the igniter, the control unit can't send a signal to the 4WD actuator and no 4WD. Do the test I wrote you above and let me know.
Good Luck.

 

I had the same problem with my Prairie. I pulled all of the fuses out and cleaned them off with contact cleaner and cleaned off the fuse box contactors. Apparently, they get a bit corroded and begin to lose connectivity over time; electronic relays are very sensitive to voltage differences too.
No more problems now. I hope that this helps.

Buzz

 

I've got a total of 31 miles on my05 Prairie 700, twice it has done the flashing. Once with 28 miles on it and I just parked it and came here to see what was happening. Next day it worked fine. Today, after a three mile ride when I stopped it was flashing again and trying to take off at an idle. I turned the key off and back on and it was all better. I checked all the connection, and wiggled everything, all seems well.

This is not acceptable......I will be calling the dealer tomorrow. 31 miles no mud, no water and already broke.....Not Happy

Kirk