Needing help 02 kawasaki prairie 650

[hangingon]

My 02 prairie 650 is hung up in 4wd when I flip the button too 2wd it show it in 2wd on the panel. I had a clunk or popping noise just one time in the front on take off. I think it must have been hung up in 4wd then. Got home and see it was leaking diff fluid out of the front diff where the center driveshaft goes into the diff. Took it out today after cleaning everything up no sign of the leak now but found out it won't come out of 4wd any help and what to look for would be a great help. Thanks

[quadnut20]

Have you checked all your U-joints maybe its binding up some where I know about car and truck axles and diff but these should be same theory !

[Jonny450R]

the 4wd drive solenoid is bad and didn't fully disengage the front drive shaft. might wanna take a closer look at the front diff to make sure you don't have a hair line crack in the front dif. As well as where the drive shaft enters the front diff for leaks.

[pete59edsel]

Where abouts is the solenoid?

[hangingon]

Thanks guys! Quadnut my quad doesn't have u-joints it's a solid drive shaft that feeds into the front diff and the front wheels are driven by cv axels. The diff is engaged by an electronic actuator which I need to see if i'm getting power to it. Now my light is flashing back an forth from 2wd to 4wd. I also need to check the fluid level.

[Jonny450R]

right side above the clutch cover

[hangingon]

Would that be the square box on top of the cover

[hangingon]

Checked the diff oil and added very little to it to fill it to the bottom of the check & fill hole on the side of the diff. I pulled the actuator & opened it up all the gears look good no dirt or water inside armature looks good.

[marioweldinginc]

Does the servo or actuator move when its out of the case when flipping the switch?

[hangingon]

NO. I'm going to check today and see if I'm getting power to it. If I can find my meter. Thanks for all the help guys.

[hangingon]

Well I pulled the front actuator ran 12v to it and it turns also plled apart the 2wd 4wd switch it looks like it had been replaced at one time very little signs of wear on the contacts Very clean inside. It seems it's not getting power to it.

[hangingon]

I got the light to stop flashing back & forth from 2wd to 4wd I had the motor can on the actuator in the wrong position. Last thing I did was disconnect the kebc turned the key on and I could hear the front diff actuator work as far as making a running noise. Once the kebc is hooked back up you hear it's motor and the diff actuator makes no noise. When I flip the 2wd to 4wd switch it changes on the dash showing the mode it should be in. I rode it today had it in high gear and when I let off the throttle the nose of the quad takes a nose dive as if I was using the front brakes.

[hangingon]

Jonny450r what would the solenoid look like and when you say it did not fully disengage the front drive shaft would that be from the motor & trans end or does it disengage at the front diff. If anyone knows jump in and help please. The yellow diff lock lever still works and locks the diff like it should.

[hangingon]

Ok one last thing. Let me know what you think or know. I'm not sure but this may be my front diff problem take a look! The actuator does work as far as turning but I think the one part is so worn it's not putting enough pressure on the part that engages and disengages the diff.

[pete59edsel]

Yes it DOES look wore....replace, but, how easy does that separate? Or does it...

[Jonny450R]

Would that be the square box on top of the cover

yes, by the way you have a PM if that doesn't fix it.

[hangingon]

Hey guys thanks Pete it does look like it would come apart The one side that isn't in bad shape you can see a pin but it looks at this point it will have to be drilled out. If I can just get the 1 part and a new pin. A friend of mine konws of an atv salvage yard in Alabama and knows the owner well. He is going to check with him for the replacement part or just a compelet actuator.

[Jonny450R]

Hey guys thanks Pete it does look like it would come apart The one side that isn't in bad shape you can see a pin but it looks at this point it will have to be drilled out. If I can just get the 1 part and a new pin. A friend of mine konws of an atv salvage yard in Alabama and knows the owner well. He is going to check with him for the replacement part or just a compelet actuator.

Might wanna have him look for parts for a suzuki twin peaks 700, same quad as a kawasaki prairie.

[hangingon]

Thanks I did do that. I had read as much as I could find on the prairie & found also that they had the deal with Suzuki on the twin peaks 700.

[Jonny450R]

Thanks I did do that. I had read as much as I could find on the prairie & found also that they had the deal with Suzuki on the twin peaks 700.

I figured you did but a lot of people don't know that in 2003 &2004 kawie pretty much made suzuki's quad line. They just had different color plastics twin peaks is a prairie and a LTZ400 is a KFX400

[hangingon]

I did not know about the LTZ & KFX