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Discussion Starter #1
took my teryx to the dyno today to tune new engine kit ,while running bout 60 it jumped into 4x4 by its self ,now it will not unlock the switch is working fine and moveing leaver on front diff but want unlock tryied to pull the aculator out and it will not come all the way out ,any one ever had this problem. dont know why this happen unless it created so much vacum at a high rpm:confused::(
 

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Well if you didnt unhook your front drive shaft you welded the front diff bushing in the yoke to the driveshaft causing it to lock in 4 wheel drive. Your looking at about a 5 hr job and $138 in parts.. One yoke, inner seal, and outer seal.. It is much easier to completly remove the front diff and do it on a bench. Good luck.
 

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Discussion Starter #4
thats my luck ,recon what caused it to go to 4x4 on its on,it still pulls just locked ,made a hell of a rackot thought it busted tranny
 

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thats my luck ,recon what caused it to go to 4x4 on its on,it still pulls just locked ,made a hell of a rackot thought it busted tranny
Bigdaddy, thanks for pointing it out that I did it twice!! :laugh:


The way the 4wd works is there is a coupler riding on splines on the input shaft, the front yoke spins on the end of the shaft where there is no splines on a brass bushing until you put it in 4wd and the coupler slides back and engages dog teeth on the face of the yoke which connects the yoke to the shaft now via the splines on the shaft, so what happen was it got so hot spinning on the shaft that it welded itself to the front input shaft hence you are in 4wd until you repair it.

KYwildcat was right on the money.

This can be done with the front diff in vehicle, not sure which way is better. Also depends on whether it hurt the front input shaft.

Always unhook the front drive shaft on a dyno and if your spinning tires excessively in 2wd put it in 4wd
 

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Discussion Starter #7
thanks for the replys ,guess ya live and learn hear latly its been some expencive learning,have one more ? ,i cant get it to take the gas as soon as i nail it ,it waits a second and then comes in is it in the clutch or just fuel injection not busting up just hesentant i really dont like that for what i have spent we tried every thing on the dyno to get it out helpted leaning at lower rpm,this computer stuff is really complicated to me.
 

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thanks for the replys ,guess ya live and learn hear latly its been some expencive learning,have one more ? ,i cant get it to take the gas as soon as i nail it ,it waits a second and then comes in is it in the clutch or just fuel injection not busting up just hesentant i really dont like that for what i have spent we tried every thing on the dyno to get it out helpted leaning at lower rpm,this computer stuff is really complicated to me.
Engine kit or stock engine?
 

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thanks for the replys ,guess ya live and learn hear latly its been some expencive learning,have one more ? ,i cant get it to take the gas as soon as i nail it ,it waits a second and then comes in is it in the clutch or just fuel injection not busting up just hesentant i really dont like that for what i have spent we tried every thing on the dyno to get it out helpted leaning at lower rpm,this computer stuff is really complicated to me.
Merlin had the same issue with his.. And he makes big HP. We tried all kinds of mapping and it wouldnt take the hesitation out. End up raising the stall in the clutch kit and now he can just punch it and HOLD ON.
 

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thanks for the replys ,guess ya live and learn hear latly its been some expencive learning,have one more ? ,i cant get it to take the gas as soon as i nail it ,it waits a second and then comes in is it in the clutch or just fuel injection not busting up just hesentant i really dont like that for what i have spent we tried every thing on the dyno to get it out helpted leaning at lower rpm,this computer stuff is really complicated to me.
I am assuming you are running a MSD. Try adding some timing advance, that should help you out.
 

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Discussion Starter #12
well i put some synthetic royal purple in the front diff ,rode half a day now it werking again ,but broke a rear axle ,cant have nothing ,as for the engine its a standard bore 12.1 stage two cams bigger injectors with msd and muzzy pro were goning to do alil to the clutch and try to get it to take off ,,guess the front diff just needed some oil and a lil gassin ha ha .
 

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well i put some synthetic royal purple in the front diff ,rode half a day now it werking again ,but broke a rear axle ,cant have nothing ,as for the engine its a standard bore 12.1 stage two cams bigger injectors with msd and muzzy pro were goning to do alil to the clutch and try to get it to take off ,,guess the front diff just needed some oil and a lil gassin ha ha .
I'm pretty sure you didn't get away with it like that. It did damage I promise you, probably should have stopped when it was locked up and removed the yoke, could have removed the frozen bushing on shaft, now it might have ruined the front input shaft and surely the inner seal is gone.
 

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Discussion Starter #14
yea im sure theres somthing else wrong bet it not leaking or making any noise probly gona pull it out just to see .
 

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where have you been KYW, have not seen you in a while??
Man I have been busier than a one armed paper hanger. Havent had time to be on forums. Missed alot, I have private messages 3 months old.. I have had a busy summer. Building cages an doing engine work. On top of that my primary job is busy as ever. Diesel engines and heavy eqpt. I am going to get back on here more often. Got my bike in one sweet condition. Custom cage & roof with all my other goodies and along with a dialed in clutch a engine to match and my bike is better than ever. Can-am and XP's still walk away from Merlin's and my bike shakin there heads in disbelief. :D Love my Rex and going to be at Black Mtn on Halloween weekend destroying trails. I will try to post more often to help guys out.. Just have to make time.
 
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