after many looks at the post on here.. im at my whits end.. here is my issue:

Bike: 05 700efi DE jr SE.

Problem: The pod say I am disengaged from 4wheel drive, however its not unlocking. I have done the following to correct this issue without luck
1. Ive changed the fluid at the front gear case
2. Ive greased the fitting on the back side of the front shocks that the front wheel bearings are housed in.
3. Ive taken the 4 wire plug out of the pod and cleaned the connectors.

Now.. Ive got service manual and Im going tomm to check the 2 wire plug that goes to the coil that engages the 4wheel drive, but if the ohms and voltage test ok, what else can be causing this not unlock? Im trying my best not to be take the
front diff out but if I have to then oh well.. any thoughts?

Oh and to add.. The pod is telling me that awd is engaged when i click on to it,, and cuts off when I switch back so I know Im getting power to the pod.. I have to believe its in that white 2 wire coil plug but Im just not sure.

 

the only bad thing i might say is it might be the roller cage inside the housing thats broke. people claaim when it breaks it sometimes locks in the front end. personally i think you would have heard it when it broke but i dont know. just an idear.

 

If that is it.. what kinda cost am I looking at to fix it?

 

you dont want to know! i dont know if that would be it or not, does it unlock at all when you mess w/ the switch or backing up? i looked one up a while ago and the part i think was $210.00. i

 

8 ASM,ROLL CAGE ([Incl. Spring and Roll Cage] )
3234455 (replaces 3234167) 1 $220.49
this is the pn# for an 05' 700 efi

 

Jesus Christ.. I hope not.. Naaa..it doesnt come out at all.. backing up or going forward .. Im hoping itll be the coil wire plug.

 

i hope it is too. like i said i think you would here some noises if it was broke. good luck w/ it and let us know.

 

Uh, I think you broke the Hilliard Clutch in front Diff. See my post from last night(broken Hilliard). I have broken 7 of them in 3 years. The plastic is probably wedging the roller bearings into the ring carrier, If you "bag it " in rverse it should crunch a bit and disengage. Hopefully you didnt crack the ring gear carrier cause that is real expensive (been there, done that) If anyone knows why they keep breaking let us know! is there a setting with the little nut&screw on side of diff case?

 

just so you know, looks like they had 2 differnt ones for that year.


ASM-GEARCASE,FRONT (If built before 6/13/05)
1332428 (replaces 1341497) 1 $818.99


ASM-GEARCASE,FRONT (If built after 6/13/05)
1332428 1 $818.99
hope its something simple and notthe roller/clutch both real expensive. let us know.

 

Well...in a few hours Im going to rip into this thing... however I cant take the diff apart today.. ive got a special person
that wants to ride on it with me tomm..and its got to be running.. ill check the coil plug and a few other things. ill let you know.