Flashing 2WD/4WD

[toadmax]

Just got back from the Rocky mountain ATV Jamboree and had problems everyday with tripping the flashing 2WD/4WD error code and disabling the engine brake and 4 wheel drive actuators.I ran into 3 other 650 prairie owners who had the same exact problem.Kawasaki was the sponsor of the event and had a rep and tech guy on site.The first day the tech guy checked it out pulled the fuse and cleaned it with contact cleaner and replaced it and everything was fine.The next morning on the ride it tripped again,so I cleaned it again and bent the legs a little to make better contact and it worked again.It tripped again the next day.I was back at the motel working on it when another prairie owner came and knew what problem I was having.He said he had the same problem and went to see the guys at the Kawasaki trailer and they told him to clean it and then put diaelectric grease around all the fuses to keep water and dust out.He said he has not had a problem since.Mine though tripped again the next day a couple of times, in fact I had to pull the fuse and replace it to reset right before the mud bog and sled pull just to get 4WD.At the end of the mud bog I talked to another 650 owner who asked if I had any problem with my 650.I told what was going on and he said he had the same thing and had even replaced an actuator, but was still having problems.I went back to the Kawasaki trailer and talked to the rep who told me that they had seen a few machines with this problem this week and were investigating it and to try cleaning the connections on the brain box,but that didn't help.Has anyone else had this problem?-and any luck fixing it?

[Adirondack Man]

Mine was doing it about 4 weeks ago. It did it after riding in the mud and 4wd would only work sporadically. It stopped after a couple of days and has not happened again. I just figured some moisture either got into the actuator, or the fuse, and that once it dried out, problem solved. Anyhow, that is what I am hoping!

[Mike Walker]

my first thought was that it was a code listed in the manual... but if the Kawi reps didn't know ????...I don't have my manual here, but the flashing lights increments determine which problem code is being displayed...WAM

[toadmax]

It was flashing every 2 seconds(which should be both engine brake and 4WD)

[bfb650b2]

Mine too gave me problems on the '03 P650 but not once on the '02 P650.
Mine started acting up in Moab but it fixed itself by working correctly the next 2 days while riding the Paiute Trails in the Marysvale area but by the third day I was having problems again. I was there before the Jamboree. It too was the brake/actuator but at the time, it showed it was the 4WD/actuator by the flashing seconds, & the ohm readings were incorrect on one of the set of wires. Then, oddly, the flashing showed that both units of the actuators FAILED, both the Brake & 4wd actuators. After I got home, I cleaned the fuse block, took out all of the fuses, took out the DG Holeshot, the holeshot never impressed me anyway, took the converter cover off & cleaned the dust out of it, it was very dusty in there & since then, I have not had any more problems with it, everything is working normal now.
I read here in these Forums that the DG Holeshot is sharing the 4wd actuator circuit & sense I wasn't impressed with the holeshot & since my problem started with the flashing of the 4x4/4x2 lights started after the Holeshot was installed, I removed the holeshot & the problem went away. I also read on another post somewhere, either atvsource or atvconnection about checking the convertor inside cover for excess dust, which mine did have.
Was it the Holeshot causing the problem, I really don't think so, since I did everything at once, converter cover, fuse block & holeshot removal.
bfb650Bearcat

[KISSSOFDEATH]

If I had my manual handy I could tell you which actuator that 2 sec represents. Sorry I cant help.

[toadmax]

bfb650b2..I also installed the Holeshot a few months ago and my 2WD/4WD started flashing , so I removed took it to the Dealer and had it reset and didn't have anymore problem until this weekend.I don't know if the holeshot was the problem or not. Don at DG was very responsive and even had Scott(I believe thats his name) call me direct to check a few things and wanted me to install it back on the machine and call him to run through some tests over the phone. I just haven't made time to do it yet, but was very pleased with their follow up.I have not ridden it since getting back so I don't know yet if by chance it was moisture related or not.I see by your reply that you sold your Prairie and are buying a AC 650.My friend that I went to Richfield with has a 03 AC 500 with IRS and we switch for a while towards the end of a days ride and I'll tell you it had a pretty soft ride compared to my Prairie.It obviously didn't corner like the Prairie or have anywhere near the power,but made me take notice.In fact I went with the same guy to the AC dealer today. He was looking into getting a new 650 after spending some time on my prairie.They didn't have any there, but said they had 6 coming this week. They want $7150 and $7450 for the LE. I would be curious what you paid for yours and how you compare pros and cons to your prairie

[bfb650b2]

Kisssofdeath
The service manual states every 2 seconds is the brake actuator failure.
While I was riding the Paiute trails my 4wd actuator failed, every 1 second of flashing the 4wd/2wd, then when I got home, both actuators had failed, every 4 seconds.
While at camp in Marysvale (Big rock mountain rv park) we disconnected the wire hardness for the wiring plug for the 4wd actuator, everything check out OK on the Ohm meter except for the orange/blue wires.This was also the same set of bad readings I was getting on the brake actuator, the orange/blue wires, I thought that was a bit odd. Did some researching back on the Holeshot post from the Tech & found it interesting that the holeshot is using the 4WD actuator circiut, if I read it correctly, I just added it up & decided to remove the Holeshot module. I also cleaned the Fuse holder & the dust out of the converter cover, we out this past weekend & rode in the dust ALL I could stand, on purpose to test the actuators with the DG Holeshot removed & so far, everything is working correctly.
Maybe I just have a faulty Holeshot unit, I plan on sending it back to DG & seeing if they can test the unit. I know I wired it up correctly. If it was a faulty unit & if I can get a replacement unit then I would like to try it on the Cat 650 because it comes stock with 26 inch tires.

Toadmax
You didn't state where your AC dealer is located. My Dealer, has no clue on when his 5 650's will arrive, so I am just waiting. This dealer is letting us have 2 of his Cat 650's for 6800 each w/warn winches installed but only because we are buying 2 Cat 650 units instead of one, he is giving us a price discount. My brother in-law bought my P650, so at least I still have something to ride around on.
I too had the Holeshot installed for a few months before I had problems with the actuators & as stated above to KOD, I would really like to find out if the Holeshot was a bad unit or if it checks out A'OK. If it checks out A'OK, then I will not install it again.
bfb650Bearcat

[Bearman]

Hi Guys
Just got back from vacation, I was also at the atv jamboree in utah. Several 02 and 03 Prairie 650 and 700 in our group rode 500 to 600 miles in 5 days with holeshot installed and had no problems. Oldman wheeler was there with his 700 Prairie, holeshot and snorkel installed and as far as I know had no problems. The key is to keep your belt tight and blow the dust out from the belt and cover. Scott will be happy to test any holeshot for problems if you want to send them back but they are tested before packaging and I doubt if they are bad. The holeshot adds a lot more torque and especially if you are running larger tires you will need to keep up on your belt maintanence. If your not impressed with the holeshots performance I have to wonder if it is hooked up correctly or if something else is wrong. Scott says mid to late October we will be taking orders on the unlimiter and of course it will be announced here first
Thanks
Don

[bfb650b2]

Bearman
I am using the Kawasaki high altitude clutch kit in my P650, which really helps my low end power from a dead start & continues throughout the powerband. With so many of these forums anymore, it is hard to remember where you read certain info on everything that we install on our 4wheelers & the do's & don'ts for aftermarket add-ons. I read at one of these Forums that you should not use your Holeshot for : example, with my H/A kit, as the Holeshot is designed to be used with a stock clutch set-up, other than the black spring mod. Is this true? I even had a friend check the wiring of the Holeshot since he had a Holeshot in his P650 & my P650 was Wired correctly.
My belt is tight with the .006 shim in before I had both shims out but it was just too embarrasing with all of that noise while out riding with my buddies, so when I met a fellow rider in Silverton Co, we put the thinnest shim back in.
I didn't know about the converter dust problem till after I returned from our ATV trip, odd, my first '02 P650 never had a actuator problem in the hole 1300 miles that it was ridden & out here in NM is allot of dust.
If more than just a few of us were having actuator problems with the DG Holeshot installed, then I would say there is a Problem but since I am not seeing that many complaints, then as I stated before, I don't think it was the Holeshot. I just don't think the Holeshot works good with my present H/A clutch set-up.
bfb650Bearcat