Hope someone can help me out with this one!! Last weekend my buddies and I were out on a great run.....I tried to spray my buddy behind with mud because my switch AND my dash was showing 2WD and the front wheels kicked in. I tried several times throughout the rest of the trip flicking the switch but it would not come out. My battery light did not come on like it usually does when it's low or when I'm running all the accessories. There are no noises or anything like that coming from the front end. The bike is working great it just won't come out of AWD.

 

Sounds like you blew the rollar cage in the front diff or it is going to go. When these go it is usually because it kicks into 4wd while doing a brake torque or doing doughnuts on ice, snow, mud. First off what year and model is it? You can unplug the wires going to the front diff to see if it will release. If not then you will have to tear the diff apart because something is stuck, broke or ready to break. The rollar cages are plastic and will break under a load. I just replaced a diff in my brotherinlaws sp600 and rebuilt a diff in my friends sp700. Both of them the rollar cage broke but my brotherinlaw kept driving his and tore alot more up.

It could also be the armature plate in the diff. Either way if you unplug the power to the diff and it does not come out then you need to pull it apart.

 

It's an 2004 Sportman 700 carb.

 

Thanks.....I'll let you know the outcome.

 

Better than mine.Mines stuck in 2 wheel drive. (cuz I aint got a 4x4).

 

I get the same problem every six months or so. Mine is due to the fact that the rear seal leaks a tiny bit of water. That creates a little surface rust on the rollers that are in the cage. When that happens it will hang in AWD mode even with the switch off.
You need to try opening up the diff and checking for surface rust. If even just a little it can cause the symptoms you are explaining. Wire brush the rollers coat it with PB Blaster and put back together.
Hope this is your problaem, wont cost ya anything.. If ya need new side seals I know the Advance Auto Parts Parts Number so you dont have to pay the Stealer for them.

bUg

 

well if it was a honda or yamaha it wouldnt get stuck get a real 4 wheeler[img]i/expressions/face-icon-small-tongue.gif[/img]

 

Yfx250,

Man you are origional. I like your thinking. NOT!!! Morron. Get a life.

 

LOL, get a 3 1/2 wheel drive Honda or a itsy bitsy framed yamaha Ha Ha HA Ha