2005 500 sportsman

[cjcj1982]

4x4 wont engage switch lights up axles turn to the hubs and the wheel bearings are good im thinking actuator but dont know where it is or how to test it help would be appreciated

[blueline15]

how have you tested that the 4x4 is not working? did you get stuck and just got the rear wheels spinning?

[Bruce!]

And welcome to the board!

[cjcj1982]

alright this bike is actually a 2003 i was wrong and i found out this is a different 4x4 system to check the 4x4 i jack all wheels off the ground and then just the rear the front never turned this 4x4 has wires going to each hub and neither one is engaging i dont think its mechanical i think it is electrical any ideas? thanks

[blueline15]

i have a pretty good idea with the 4x4 system you are dealing with from my few years of doing parts.

both outside hubs have fluid in them. you can start with putting in new fluid to see if that helps, but im going to guess that #15, the magnet, is bad. i cant tell you how many times i have had to order that part when 4x4 on this system wasnt engaging.


# Add Part# Description Quantity
1 5411608 Bumper 2 Usage
2 7041761 Strut, Front 2 Usage
3 5211115 Washer 2 Usage
4 7558402 Washer, Flat 10 Usage
4 7558402 Washer, Flat 10 Usage
4 7558402 Washer, Flat 10 Usage
5 7080367 Clamp 2 Usage
6 7542324 Nut, Nylok 4 Usage
7 7512365 Screw 4 Usage
8 7552901 Washer, Spring Lock 4 Usage
9 5810439 Retainer, Casting Wire, Strut 2 Usage
10 ------- ASM., FRONT BRAKE CALIPER, RH [SEE FRONT BRAKE PG. B5 FOR DETAILS] 1 Usage
11 3554509 Bearing, Tapered Roller 4 Usage
11 3554509 Bearing, Tapered Roller 4 Usage
12 3554507 Bearing, Tapered Roller Cup 4 Usage
12 3554507 Bearing, Tapered Roller Cup 4 Usage
13 5222193 Sleeve, Hubstrut Seal 2 Usage
14 7080306 Fitting, Lubrication 2 Usage
15 2410133 Coil, Magnetic 2 Usage
16 1820950 Asm., Hubstrut, Heavy, LH [42mm][Incl. 9,12-15,23] 1 Usage
16 1820951 Asm., Hubstrut, Heavy, RH [42mm][Incl. 9,12-15,23] 1 Usage
17 7041375-067 Spring, Compression, Black 2 Usage
17 7041375-293 Spring, Compression, Red 2 Usage
18 5243364 Retainer, Spring 2 Usage
19 5432871 Ball, Pivot, Bottom 2 Usage
20 7515339 Bolt 4 Usage
21 5132062 Spacer 2 Usage
22 ------- KIT, DRIVE SHAFT W/SLEEVE BTB [SEE DRIVE SHAFT PG. B2, REF. 12] 1 Usage
23 3610028 Seal, Hubstrut 2 Usage
24 5432872 Ball, Pivot, Top 2 Usage
25 5810291 Spacer, Rubber 2 Usage
26 7555749 Washer 2 Usage
27 7547104 Nut, Nylok

[cjcj1982]

thanks for the info i'll give it a try. the only reason i thought that wouldnt do it is (and i may be wrong) because both hubs are not turning that would mean that both sides the magnet would be bad. my thinking was that they work independent of each other it would be by chance that both are bad hey i may be wrong i was looking for something that swit

[blueline15]

has anyone pulled the front end apart lately?

[cjcj1982]

no one has pulled the front end apart i looked into the magnets there a little pricey to replace and hope to get lucky i was wanting to try and manually hook to the wires and see if that will work is this possible? maybe put 12v to the wires or they may work of a negative i dont know any ideas