Hisun 400XL 2012 difflock light burns all the time

[Jaskafin]

When i put power on it takes couple seconds and difflock light starts to burn but His is 2wd. I opened the front servomotor unit but no help. Fuses are ok, Relays are ok. Power is on limpmode when the difflight burns.. Whatta hell is problem. Will it help if i brake the light from the dash...

Edited October 16, 2022 by Jaskafin
Fix

[Mech]

Is this meant to have an auto engage diff lock does it ? If it detects slip it engages ? Do you have a service manual ?

I'd check the diff is working..  getting drive to the ground.. I'd jack one side of the bike at a time, put it in four wheel drive, and try turning the raised wheel.

If the diff and front drive is working then I'd test the diff lock solenoid is getting power to it, and that it has a good earth, and I'd check the wheel rotation measuring devices if it has any.

[Mech]

There's a 2014 manual here...

https://www.manualslib.com/h/hisun+400xl.html 

You should follow their testing and diagnostic process.

[Jaskafin]

5 hours ago, Mech said:

Is this meant to have an auto engage diff lock does it ? If it detects slip it engages ? Do you have a service manual ?

I'd check the diff is working..  getting drive to the ground.. I'd jack one side of the bike at a time, put it in four wheel drive, and try turning the raised wheel.

If the diff and front drive is working then I'd test the diff lock solenoid is getting power to it, and that it has a good earth, and I'd check the wheel rotation measuring devices if it has any.

Thanks mate for answering. Hisun has servomotor controlled on front axle. 2 buttons on handlebar that controls thst servomotor. Fron 2wd to 4wd ja second button is 4wd to Difflock. 

4wd and Difflock works like it should be but it burns difflock light even when i have  2wd selected. I took controlwires away from diff but still light burns so  the problem is not on servomotor 

[Jaskafin]

5 hours ago, Mech said:

There's a 2014 manual here...

https://www.manualslib.com/h/hisun+400xl.html 

You should follow their testing and diagnostic process.

UTV has different wiring than ATV.  

[Mech]

Did you look at that manual ?

There are a heap of solenoids, switches and fuses, and it's too much for me to walk you through if you don't do the leg work yourself.

Start reading/following the manuals instructions and let me know what you find and I'll try to help.

[Mech]

Tell me in the mean time.. when you say "When i put power on it takes couple seconds and difflock light starts to burn...", do you mean when you turn the key on, when you use the throttle, or when you start pushing it along a bit, using a lot of power ?

And, do you have a manual for the vehicle you have, and is it for downloadable.. Best if we are both looking at the same manual..

[Jaskafin]

31 minutes ago, Mech said:

Tell me in the mean time.. when you say "When i put power on it takes couple seconds and difflock light starts to burn...", do you mean when you turn the key on, when you use the throttle, or when you start pushing it along a bit, using a lot of power ?

And, do you have a manual for the vehicle you have, and is it for downloadable.. Best if we are both looking at the same manual..

Yes. When i turn key to on position, it takes couple seconds and that difflock light starts to burn. 2wd is selected on controls. 

No manual came when i bought it.  I have tried to find manual or wiringdiags but havent found yet

Just now, Jaskafin said:

Yes. When i turn key to on position, it takes couple seconds and that difflock light starts to burn. 2wd is selected on controls. 

No manual came when i bought it.  I have tried to find manual or wiringdiags but havent found yet

 

[Mech]

Oh ok.. That manual I pointed to was for a 400xl.. There was no mention of a quad version..

I think we really need a wiring diagram.. Are you sure the wiring is different ?  A lot of what you describe sounds much the same as that side by side.. Perhaps if you download the manual, and have a look, and see if it seem to be the same switch gear and relays etc we might be able to figure where to start.

Do you know, does that quad have trouble codes, and have you read them ?

[Mech]

The 500ATV2 manual might be similar.. ?  Have a look and see if the switches etc are the same.. Perhaps we can match up a wiring diagram even if the wire  colours are not right.

https://www.manualslib.com/brand/hisun/offroad-vehicle.html

I see there is also a 450 model atv.. 

You need to inspect each of those links, the descriptions are not all accurate..  Some links take you to a different model than the link says.. 

[Mech]

I see it's known as a Forge 400 too.. and that it's the same as a 360..

https://www.ebay.com/itm/332948942221

[Jaskafin]

2 hours ago, Mech said:

Oh ok.. That manual I pointed to was for a 400xl.. There was no mention of a quad version..

I think we really need a wiring diagram.. Are you sure the wiring is different ?  A lot of what you describe sounds much the same as that side by side.. Perhaps if you download the manual, and have a look, and see if it seem to be the same switch gear and relays etc we might be able to figure where to start.

Do you know, does that quad have trouble codes, and have you read them ?

How i can read the codes

[Mech]

Well... in some models the trouble codes get displayed automatically if there is a fault. They get displayed in the clock display. If you don't have that then it won't I think have trouble codes.

I'm not familiar with those quads, and information is scarce. The manuals I've been looking at show different systems.

It really needs you to look at several manuals and see if you can find one with a very similar set up.

If you showed us some pictures of your switch gear, and dash, it might help me to figure what setup is on your bike, but I'd still have to keep coming back in asking you to confirm things..

The nearest model I've found is for the 500. It's wiring diagram(all of the wiring diagrams actually), doesn't have any things labeled. It all needs comparing to your bike and confirming..

About the only thing I can figure is that the two second delay before the light comes on is significant. There's two likely causes for that. One is that some electronic component is getting hot and making the light come on, and the other possibility is that the bike has a computer and it takes two seconds to do it's system checks and find a fault which causes the light to come on.. but I don't know whether your bike has a computer. a picture of the dash would help there..  Maybe.

If you can identify a quad setup that looks like it has the same fuel system(fuel injected or carby),switches, ignition, fuses, relays etc, then we could probably assume it's wiring will be very similar, but possibly with different coloured wires, which is common. Then we might get somewhere.

At the moment, having looked a  few models, it's looking to me that the component they describe as the cdi is a suspect. They describe it as a cdi, but it has far too many wires and some of them go to the diff lock light.. It must be more than a cdi, perhaps a computer that does the ignition and other jobs as well. In the 500 model, power goes through that cdi, then to the diff lock actuator and to the diff lock light, then to a normally closed switch, which looks like it could be some sort of over ride for the diff lock light.. That switch isn't labeled though and it's unclear where it is on the bike.

We really need to confirm what the bike has on it and which other models are similar.

 

[Mech]

Ok, I did some more reading..  That actuator on the front diff... how many wires does it have going to it ?