SInce my 4WD has quit working, I have found that I am not getting the right power supply to the controller (4.6v instead of 12v+) when I turn the ignition switch on. Therefore it seems that I have a bad connection or bad wire between the ignition and the controller, or the ignition switch is bad. Can anyone tell me how to test the wires for continuity, and how to test the ignition switch.

BTW, everything else works normal, EBC, speedo, starts fine, runs fine, actuator is fine...already checked all of this out, looking at electrical now.

 

Power to controller:

Red/White is 12v from fuse block (10 amp fuse, always on)
Brown is 12v from fuse block (5amp fuse, when key swtich on) This is just a signal, it runs off the same circuit as a whole bunch of other stuff.
Black/Yello is ground.

The ign switch only has two outputs, one runs all the accessory stuff, and the other signals the CDI. It isn't hard to test that switch. If engine runs and u got bright headlights means both poles are ok.

 

Scooter If you want I can email you the wiring diadram if you think it might help.

 

Scoot, with everything that you have checked, if I was a betting man, I would bet ya a nickel that your Actuator Controller is bad.

 

Really don't think it is the actuator, seems to me to be a blatant power failure somewhere between the ignition switch and the controller. If I had the proper voltage there, I think all would work. I am going to take off the front plastic and do some wire chasing and see if I can find it.

When I put my snorkle on. I had a hell of a time getting the snorkle back in, does everyone take off the plastic to do this? If so, maybe in my fighting to get it back in I damaged a wire. As I said before, it did work intermittently one day, but hasn't since. Maybe I did something, that is what I am going to look for by taking the plastic off...

 

Scoot I had a 02 green 650 and traded it for the 03 Cami 650. The first day out with my new Camo I noticed that the seat was hard to latch wouldn't stay latched. I looked around trying to figure what the problem was with the seat and noticed the wiring harness that is supposed the lay in front of and to the left side of the Actuator Controller was running across the top of the actuator controller. When I would try to close the seat down the wiring harness would set between the actuator controller and the seat causing the clearance needed to close the seat not to be there. Later in the same day I could no longer get the 650 to go into 4 wheel drive. Took the 650 to the shop the next day and we replaced the actuator controller and all was well.

I don't know if the pressure of the wiring harness, being trapped between the Actuator Controller and the seat with me setting on the seat, damaged the controller or not. This I hope has nothing to do with your problem but I wanted to share it with you. Good luck and I hope you find a damaged wire.

 

scooter650

Check your fuse. Not to see if its burnt out but to see if its coroded inside the fuse holder had a few now that have gotten the right kind of slough water inside the fuse holder and they got pretty fuzzy inside. Other than that we havn't had much for problems with the 4x4 on these machines other than the odd accuator failure in which case they just up and quit. Just a thought.

 

sounds like you should check all the fuses...........

and all connections

 

Bump...I was just wondering if you found your problem Scooter?

 

I have not "found" the problem yet, but I think I know what it is. I need to take off the front plastic and do some looking, but I believe that I damaged a wire when I was putting my snorkle mod on. I went in through the bottom and had a hell of a time getting it in there, since I did not take off any plastic to do it, and I am pretty sure that I damaged a wire or got a connnector loose. I am not positive of this, but it should be warming up here this week, so I will try and get it done. Want to ride one day and get the plastic off the other.