A tale of frustration and ultimately relief

The 2wd/4wd light went on last fall, signaled front actuator which had been damaged in mud. Guys here helped me find a cheap one at Ron Ayers. Important note, original unit had a vent which allowed the water in, new oem unit from Ron Ayers does not have this vent. Installed actuator, didn't fully engage. Checked every connection and fuse, got frustrated and locked it into 4wd for snow season.

FFWD to a few weeks ago. New 27" mudlites on Type 7's (12"), looking to replace secondary. Tear bike apart, don't install spring (didn't have it yet and wanted to ride), and put it back together. Belt light tripped along the way. Got reset instructions from nyroc's site, but didn't work.

So at this point the 2wd/4wd light and belt lights are on. The bike won't switch b/w 2/4wd and she's in limp mode. We'd had all we could take. I'm thinking it's going to be another 250 or so for a new kbec actuator or controller, and if that's the case I'm just going to get the DG and drop kbec altogether for 90 bucks.

Took to family friend at dealership, found out 02-03 procedure different from 04-05 for the belt reset. Also found out that the actual 2/4wd switch on the handlebars is what went bad, maybe even all along. Ordered new secondary spring while it's there and should have her back and running next week.

Just thought I'd share this with you guys, part as a thank you for helping me out, and partly to help out others going through the same issues, or at least let them know they're not alone.

 

Got the new switch in...KEBC box on order now...[img]i/expressions/face-icon-small-mad.gif[/img]

 

Change your brake actuator!!!!!!!!!!!!!!!!!!![img]i/expressions/face-icon-small-wink.gif[/img]

 

On your clutch cover[img]i/expressions/face-icon-small-wink.gif[/img]

 

We did found some broken or corroded wire but that is a complicated set up to find the wire but it can be repaired good luck!!!! [img]i/expressions/face-icon-small-smile.gif[/img]

 

No, it was the kbec box, the 4wd switch, and the 4wd actuator. The kbec one was the only thing that worked. In retrospect it would've been nice just to eliminate it all together but I needed it running at the time.

 

I hate this Kawasaki...Flashing lights again...

 

Does your 4wd work.

 

Yep, have been very careful not to hit the switch. Light started flashing when it was already in 4wd, and we've kept it there.