[Kinb]

I have a 2009 foreman 500 and the 4x4 light comes on but the 4x4 won’t work, I’ve done some troubleshooting and the front diff and shafts are fine. I tested the voltage from the switch and I get 7.04v with the switch in the 2wd and 4wd position. I can hear a click when it’s switched from 2 to 4. Does anyone know if this is the correct voltage or have any other idea what could be wrong

 

[Jeepwm69]

Sounds like your actuator is bad if there is voltage going to the actuator. Did you measure it on the orange and white wire going to the green plug on the front diff to make sure voltage is getting all the way to the actuator?

 

[shadetree]

did you run a test on the speed sensors ?. I don't know if that model has them ?, but if it does ?, then the front won't work until the speed sensors work.

 

[Kinb]

I did check at the voltage at the diff. The speedometer is working does that mean the speed sensors are working.

 

[shadetree]

I did check at the voltage at the diff. The speedometer is working does that mean the speed sensors are working.

no, just means your getting power to the meter, has nothing to do with a bad speed sensor. I know the 2003 trx450's have not 1 , but 2 speed sensors on them just on the front diff alone !.

 

[retro]

I did check at the voltage at the diff. The speedometer is working does that mean the speed sensors are working.

If you measure 7.04 volts between the orange/black wire & the white/black wire supplying the clutch coil when you push the switch to 4wd, AND you can hear the selectable clutch click when it receives that voltage, then the selectable clutch is working. If the diff still does not work after clutch engagement, then its the pinion shaft spline that has stripped out. In that case you'd have to replace the clutch/pinion shaft assembly by removing the driveshaft and unbolting it from the rear of the diff housing... 3 bolts I think...

Before going any further though, unplug the selectable clutch harness from the bike. Using two jumper wires temporarily apply positive battery voltage to the orange/black wire and negative ground the white/black wire feeding the clutch coil. Then test to see if 4wd works. If so, then the 7.04 volts that the ECM is supplying to the clutch is not enough to hold the clutch coil fully engaged. Let us know how it goes...

EDIT:
I gave ya the wrong wire colors. See the attachment for TRX500FM wire colors to the clutch coil.

 

[Kinb]

I’ll try that over the weekend thanks