So I know that this has been addressed in other posts dealing with these lights, but i still cant figure it out. My 4x4 light flashes in 1 second intervals i think? (1 sec on one sec off??) What has me stumped is that it doesnt always flash, meaning doesnt come on automatically and most often it only comes on after driving it around a while and it comes on most often when i am slowing down and not when i am just accelerating. This leads me to believe that it is the engine brake actuator because sometimes when riding it makes some weird noises and when i turn the key off it makes some weird noises, different than the noise it usually makes when it shuts off (is it supposed to make a noise). Anybody have any advice? Can i clean it or do any maintainence on it because i think that is my problem and btw its connections are clean and the machine runs great besides this. 4x4 also seems to engage and disengage with the switch even when the light is flashing. HELP

 

Your observation is correct that your engine brake actuator (12 volt servo motor) or reltated component is going bad. Since you are saying that you are hearing some abnormal noise, I suspect either the drive converter bearing (where the teflon fingers are pressing against) is going bad/worn out or the actuator motor itself. Also, check the teflon finger for wear. You need to open up the CVT cover to inspect the bearing. The actuator motor can be disassembled and the gears can be checked/cleaned/lubed but NOT the motor itself or the potentiometer. Check those 3 components.

 

ok so i took apart the little engine brake piece. Im not sure what you were talking about by "fingers" but this is what i did. I checked out that tall magnetic like piece and it was crystal clean so i did nothing to that. I took the other piece apart with the gears in it and put a little grease on them and when i put it back together and turned the key on and off it sounded better than it did before, like it should sound i guess, no "abnormal" weird noises i think. But i wanted to try it out by running it around the block the light did come back on. Im wondering if my battery could be causing this. Yes the battery is pretty much shot, i always have to pull start it and it will never recharge. At one point i was trying to remove the battery to replace it but i couldnt because the negative terminal screw was rusted together and actually a piece of that terminal broke off when i was trying to remove it, but since i hardly use the machine i just decided to leave it like that since it still pull started. When the battery was good i dont ever remember having the flashing problem. Obviously my next step is to just change out the battery, right?

 

Yes, I agree with your plan of attack. Get a fresh battery asap and go from there. The engine brake system HEAVILY depends on the battery since dc motor and potentiometer all depending on the voltage value.

The Teflnon fingers (2) are like metal forks sticking out vertically downward and attached at the bottom of the engine brake acuator inside the cvt cover. If you remove the cvt cover and look inside the cover, you can't miss it. Then look at teh center of the drive converter where the two fingers would be pressing against.

You must understand how the system works before attempting to work on it. This applies to anything and everything not only atv...