There is another forum about this, but it is very old and inconclusive as to the determination of the actual problem.
I have an 05' Eiger that has been sitting for several years. It belongs to my brother-in-law and I am fixing it for him. It's in great shape and I got it running again. I noticed the front tires are very bald and discovered its stuck in 4x4.

I've checked the 4x4/2x4 lever inside and out. There are no broken components and appears to be functioning properly. I've checked where that cable goes into the back of the front differential and it also seems to be functioning properly.
I have tightened and loosened the lever adjustment in the cable, just below the handlebar lever with no difference.

I've driven the ATV backwards for a long distance with the lever in 2wd, while vigorously turning the handlebars left and right with no change.

These were all suggestions I've read online. Any other suggestions? I'm at a loss and just want it to work properly before I give up on it and give it back to my brother-in-law. I am grateful I got it running again and I realize it's better to be stuck in 4x4 than in 2x4, but I still want to fix it. Do I need to pull the differential off and tear it open maybe? Sounds terrible...

 

Almost certain to be the cable. 90s Suzukis had a reputation for stretchy cables. By the Eiger they had almost fixed this but just for old times sake, stuck that thin, nasty cable with it's stupidly placed adjuster on for the 2wd/4wd. I have had to replace several that simply ran out of adjustment. As the set up is springy, it can take a rev or two to get the mechanism to pop out of 4WD even with the cable correct, but pull the shaft out at the bottom by hand, and turn a wheel and it should come out. If it does, fit a new cable, and best of luck getting the old one out at the diff end.

 

Are you saying to just get a new cable for it and that should do the trick? When I engage the lever, the brass fitting (plunger) at the end of the cable that goes into the diff goes in and out about 1/4 inch. I don't know what it (should) feel like when I engage the lever or how far the plunger is supposed to go in and out. There isn't much pressure when I move the lever. So again, you think it would be best to just replace the cable all together?

 

It is a steel plunger and moves in and out a lot more than 1/4" with a correctly adjusted cable. It is a while since I did one so can't remember how much. Can't remember which way it works but think in is engaged, disengaged out. Whatever, spring pressure should pull it in with the cable correct, and you can pull it out with pliers to check that it does work, turning a raised front wheel so you know when it has. If it does, but you can't get the cable adjusted enough to do it, get a new cable.

 

Thank you for the info. I ordered a new cable last night. I'll post back here once I install and test it out.

 

That was exactly the issue. Although a visual inspection seemed to be good, I changed out the 4x4 cable anyway and it shifts in and out of 4x4 like a dream now! I appreciate the suggestion, thanks!