We have a couple Kawis, one of our 700 prarie has started to kick out of 4 wheel drive (you hear a clunking sound when this happens)w/out using the switch to take it out, however the 2WD/4WD light is not flashing back and fourth, any Kawi gurus out there with help on this?, i thought maybe the module on front diff?,(like the on KEBC one on belt housing) or mabe the 2wd/4wd selector switch (although i dont think a switch failure would be likely as they usually fail all together!? help please;

 

If the 2/4WD light not flashing, it would be a mechanical problem as following.
Remove the 2/4WD actuator assembly from the front gear case. Inspect the small (1/2" x 3/4") metal block for any wear or damage. If the corner is rounded off, replace it. Make sure you do not lose the metal sleeves for the mounting bolt holes on the actuator. If you don't install the sleeves, the actuator plastic housing can crack as you tighten the bolts.

 

Hayashi, thanks for the info, I checked on a web site micro fische and the part # for the EBC actuator and the 2x4 w/d actuator are the same?, is that the case?, also I will pull the 2/4 wd actuator off this weekend and check, if it is (the plunger end I assume) is not rounded off like you mentioned what else can it be?, will it flash between 2 and 4 wheel drive when the actuators are the problem?, 1 second (flash) for the EBC, and 2 second flash for the 2/4 w/d actuator?, thanks in advance for sharing your knowledge on this; kowi powi

 

First some answers to your ?s.

P/N same?
No, the 2 actuators have different numbers. The 2/4WD P/N is 16172-0007 and the EBC P/N is 16172-0006. They are extremely similar - mechanically same function, and the same number of wires, same color wires, same 5pin Molex pin connector but the only difference is the wirining length (2/4WD one is much longer).

Will 2/4WD flash?
Yes, if either the 2/4WD or EBC are not working properly, the light will flash between 2WD and 4WD characters back and forth on the meter. However, you need to be careful when measuring the flashing time. Are you counting half-cycle or full-cycle? Half cycle would be just one-way, either from 2WD to 4WD or 4WD to 2WD light. The full cycle time would be the total round trip time, such as from 2WD->4WD->2WD. The cycle time you descrived is the half-cycle. Since you said nothing was flashing on the meter, you should not worry about this.

Can it be the 2/4WD selector?
Not likely but a possibility. Inspect the rubber boot around the switch for any damage/cut. Even if there is some damage to the boot, the switch is very reliable (because it is so simple). The switch is OPEN for 2WD and CLOSED for 4WD (grounding the circuit to provide 12V to engage 4WD).

Then, what can it be?

You said the 2/4WD was NOT flashing - this is a very crucial info for a correct diagnose.

1). Remove the 2/4WD actuator and disconnect the connector. Put on a bench and directly apply 12VDC, (+) to red and (-) to blk wire from a 12V battery. Confirm that shaft/plunger is rotating smoothly. If not, open up the actuator housing, and inspect. You may apply some waterproof grease on those small gears and shaft at that point.

2). Speedo sensor from the righ side crankcase, just below the foot brake pedal pivot point. Inspect the black plastic connector (3-wire) housing and the connection.

3). The next suspect (most expensive) is the igniter which is supposed to provide 12V (+) to the Controller when you flip the 2/4WD switch to the 4wd position.

You will get it fixed - just don't give up.