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2002 TRX 450 Foreman - 4x4 not working right

2585 Views 1 Reply 2 Participants Last post by  retro
I have a 2002 TRX 450 Foreman S with the switch operated electric 4x4. The 4x4 is not engaging properly. I have it up on jack-stands now to diagnose the issue. What I have observed so far is:

1. At start up I can engage the 4x4 toggle switch and the front wheels will spin up through 3rd gear. They do not operate in 4th or 5th gear.
2. Once I shift into 4th or 5th gear the front wheels are no longer driven. Downshifting into 3rd, 2nd or 1st does not re-engage the front wheels.
3. Shifting into neutral and then back up into 1st does not re-engage the front wheels. Fiddling with the toggle switch while in neutral and then upshifting does not re-engage the front wheels.
4. Once shifted into 4th or higher gear the front wheel drive will not re-engage without shutting the machine off and restarting.

I have the front fender covers off an have not found a loose wire yet but I do not know where to check. Does anyone have any thoughts about this issue?

Thank you.
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I'd guess that your issue might have to do with one of the speed sensors. Check, clean & dielectric grease each harness plug first (include the clutch control unit plugs), then test again. Section 22 of the service manual for your Foreman will help you sort it out if cleaning the plugs don't help. Keep us updated if you can.

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