4WD is a no go!

[hayneser75]

Recently, I've had water problems where it's been getting into my front gearbox. I've replace all the oil seals (and bearings), but my problem now is that my 4WD is not engaging. Actually, it's engaging but I can't lock up the front differential. The 4WD sensor switches from 2WD to 4WD and I can hear it engage and one front tire spins, so my actuator is working. I've tightened the lever cable and it's not making any difference. My buddy also has a brute and his cable is looser than mine and his is locking up every time.

Originally, I blamed it on water getting in and thinning my oil, but I flushed out the water and filled it with clean oil then tried to climb a snow bank in my front yard and I can see it still doesn't engage with clean oil.

Any ideas?

[NMKAWIERIDER]

Originally Posted by hayneser75

Recently, I've had water problems where it's been getting into my front gearbox. I've replace all the oil seals (and bearings), but my problem now is that my 4WD is not engaging. Actually, it's engaging but I can't lock up the front differential. The 4WD sensor switches from 2WD to 4WD and I can hear it engage and one front tire spins, so my actuator is working. I've tightened the lever cable and it's not making any difference. My buddy also has a brute and his cable is looser than mine and his is locking up every time.

Originally, I blamed it on water getting in and thinning my oil, but I flushed out the water and filled it with clean oil then tried to climb a snow bank in my front yard and I can see it still doesn't engage with clean oil.

Any ideas?

If the actuator is engaging and the light shows to go into 4wd and one tire is driving, then the problem is either with the diff lock clutch pack or the planetary gears. The difflock is just like a small clutch pack that I am sure you saw when replacing the bearings. It can wear-down if set too tight and not engage anymore. Then there are the planetarys. Thay are on a shaft that some people are having problems with getting enough lubercation, they sease and break the shaft. Then no matter what you do, there is no joining the two sides with the ring gear. One might drive but the other sure shouldn't

I think I would jack it up, turn it on, engage the actuaror, have someone hold on the lock lever and go to each tire and see if one spins easily. If so, broke pin. If both are about the same...something with the pack or cable.

[hayneser75]

I jacked it up and gave it your test. With the diff lever pulled, I can hold one of the tires while on the throttle. I started by ordering the new clutch pack from kawi and replaced it, but after reassembling, I still have the same problem.

Where is the "Planetary" and "Ring Gear"?

Are you referring to shaft (#13107) on
h t t p://cheapcycleparts.com/model_years/2331-kawasaki-2008-brute-force-650-4x4i-KVF650-F8F/assemblies/56087

That's the only part of the diff I haven't taken apart to look at...Other than that, I couldn't find anything scored, broken, etc...

[NMKAWIERIDER]

Originally Posted by hayneser75

I jacked it up and gave it your test. With the diff lever pulled, I can hold one of the tires while on the throttle. I started by ordering the new clutch pack from kawi and replaced it, but after reassembling, I still have the same problem.

Where is the "Planetary" and "Ring Gear"?

Are you referring to shaft (#13107) on
h t t p://cheapcycleparts.com/model_years/2331-kawasaki-2008-brute-force-650-4x4i-KVF650-F8F/assemblies/56087

That's the only part of the diff I haven't taken apart to look at...Other than that, I couldn't find anything scored, broken, etc...

Yes, that is the pin that some have problems with and the two gears-49022 that ride on it.

[Adirondack Man]

NM,

I am not just saying this to blow smoke up your backside, but you are truely an incredible wealth of knowledge. Excellent information.

[NMKAWIERIDER]

Originally Posted by Adirondack Man

NM,

I am not just saying this to blow smoke up your backside, but you are truely an incredible wealth of knowledge. Excellent information.

Ahh..shucks... A lot of it comes from spending WAY too much time on some forum sites reading what others say, then looking at parts breakdowns. My background with Honda helps some too.as dated as that is.

[Slumlord]

Yeah, I totally agree! He is better than calling the dealer shop foreman! HE"S DA MAN!!!

[NMKAWIERIDER]

Don't give me too much credit..been way off base more then once or twice with these things.

What I want to know is...how is it you guys get a way bigger Avatar then I do??? hehe

[Slumlord]

We paid more!!!

[NMKAWIERIDER]

Originally Posted by Slumlord

We paid more!!!

WHAT!!! REALY!!!