2000 Suzuki Quadmaster 500 four wheel drive pops out of gear

[ghoeltin]

When my atv is put in 4 wheel, it makes some growling noises and then kicks itself out of gear. Has anyone had the front end apart with a similar problem?

[GEARHEAD01]

yes i have. i have the exact same machine. you will most likely need a complete front diff rebuild. if it pops out of 4x4 then either the lock up sprague or the detent ball and spring aren't working. At any case I highly recommend pulling the diff out and pulling it apart before you have a catastophic failure. I left mine to long and it cost me a complete front end. Send me a comment if you need any extra help. I would purchase a factory manual for the machine. i have both and the clymer one tells you squat for info.

your friendly neighbourhood mechanic.

[DirtDemon]

A bent shift fork may be a possibility too, but if you only have the problem when you shift into 4wd, gearhead may be right. Good luck.