OK, 4x4 quit working, I took actuator off and cleaned up the motor and reinstalled. It worked once then made a clunk and partially sheered off the little square part that fits inside the slider that engages the 4x4. I assume, this happened because I did not align something correctly???? But it fit in and all the bolts fit in correctly so I'm not sure.
2nd, when I look at the new / replacement actuators they are different, they just have a round cylinder and not the square block looking thing that goes into the slide. I felt inside the shaft and turned the wheels and it all still appears to be fine but my actuator is probably toast. Did they change the design of the engagement pin / block?
Does anyone have any idea what the heck I'm talking about ;-)

 

This may be a good read Nyroc's ATV info website

 

Can anyone tell me how to line up the motor on the actuator. I took apart and did not get the orientation correct, it partially sheered off the little metal foot. I need some instructions on how to align the magnets and the little foot for re-assembly. I hooked it up to a 12v 10 amp source and the actuator works perfectly, turned on and off a dozen plus times and it worked each time with out fail.
Anyone ???