Sometimes it works, but mostly NOT....the 4x4 light does come on and I changed the front hub fluid and armature plates. Its a shame because its really in good shape for its age and a blast to ride..I dont know what else to do ?? any help/insight would be appreciated.

 

Might be as simple as the sensor switch pin in the shifter lever assy not depressing the switch hard enough.Item # 7 in the parts break down.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Or possible that you can move or shim the switch up a tad so it can. Before you take it apart,jack up the machine wth all tires off the ground and see if the awd kicks in. The bulb may just be burnt out and on this later model the bulb being burnt out shouldn't affect the awd operation. If in the air the awd doesn't kick in,then check the shifter switch pin and switch.If you can't get the shifter to kick the switch on you can pop the front panel,find the grey/white wire on the circuit board and move it to a red/white terminal. When in gear, awd button pushed in,the awd should work. Red/white terminals are hot when the key is on.

 

Me and my son are playing with in now...(jacked it up in the air) had the 4x4 working good. Engaged the button and the light came on, 4x4 worked flawlessly. Turn 4x4 button off and 4x4 disengaged flawlessly. Ran through sequence several times (shifting between drive/neutral/reverse button on and off and all of the sudden it stopped working again. I also noticed the 4x4 light failed to come on sometimes.......could that be the switch pin ??

 

Sounds like the switch pin.. Hopefully you can adjust/rig it to where it will firmly push the switch and kick the awd on.

 

Should I find-move the grey/white wire to the red/white terminal instead of tampering with the shifter switch-pin or would you recommend properly adjusting the switch pin ?

 

Could the switch pin activate the AWD "light" but still fail to activate the AWD ?

 

Look at the pin and also the switch itself first. The switch just sits in a cut out in the shifter body.Possible it may just need to be shimmed up a tad. Over the years these rubber grommet type switches can collapse down or just push back a little.

 

OK....I will check the switch and pin now.

 

The switch is in the black box at the bottom of the shifter ?

 

Removed the linkage bolt, took off the ****, removed the two bolt holding the shifter and I still cant get it out.....