05 Brute Force flashing 4wd/2wd

[Roofgunner]

I made a post several months ago regarding the alternating 2wd/4wd flashing indicators which indicated the brake actuator malfunction. I reported I found nothing wrong after doing the circut test by the shop manual. The last thing I did was to clean, lube the brake actuator mechanism. So far, even in sub zero weather, the lights have not flashed and it's working fine. And no problem with going into and out of 4wd. This was better than spending money.

[Kawi]

Excellent information to pass along, thank you.

Kawi

[Roofgunner]

To give you some addtional info: There is the possibility that the brake actuator mechanism, due to dirt, primarily from the drive belt could have caused it not to operate smoothly thereby causing the fault. Although it didn't seem like much maybe it was enough to hold it up a little. Who knows. I did not detect any corrosion on any of the connections so it appears Kaw did a good job on those. However, my ATV is used around the farm and isn't submerged in water very often but I don't hesitate on on washing it off with a garden hose and never a pressure washer. I also switched to the Amsoil 0-40 wt. ATV oil and with our -12 degree weather it starts easily and I have the kit that the Kaw dealer gave me for the carbs to make it richer and this helps a bunch. Thanks!

[Patsplace]

I've just had my 4wd light flashing briefly, shut down for a coffee and sandwich and when I started up, all was well.
What did you use to clean and lube it. Brake cleaner and LPS?

Thanks,
Pat

[Roofgunner]

When mine started doing this I first (using the shop manual) identified the connections that related to the system and took them apart to make sure that they weren't the problem. There are tests in the manual that cover trouble shooting and they are not difficult. One of the tests involves the speed sensor and you have to block up the machine and move the rear wheel. After I did all this, I still had occasional flashing lights things on the dash board. It was then I decided I'd pull the convertor cover off and really look at the engine break device. So I did that and removed it from the cover, etc. and cleaned the cover and all the parts I could see. There was a bunch of convertor belt dust particles which is due to normal wear and tear and the belt was OK. I think I used some brake cleaner on a rag and cleaned everything. Then where appropriate I lubed (carefully) some grease or Never Sieze on the moving parts of the actuator mechanism being very careful to NOT get it on the little disc, and other parts that do the braking. Additionally, when you check the connections (plugs) it doesn't hurt to use some, what I call electric grease (it has copper in it) on the connections. This will preclude corrosion in the future. I found nothing wrong with the tests per the manual so I assume that the actuator mech was somehow hanging up or retarded due to the crude inside the convertor cover. Apparently it couldn't move easily thereby setting off the mal function indicator. So far, all is working well with my BF and I feel I saved alot of $$. Good luck. PS. Mine did the same as yours--when you shut it off the malfunction indicator would stop showing the problem. One more thing: Depending on the rate of flashing of the 2wd/4wd indicators will determine whether or not it's the engine brake or the front 4wd engagement mech!!

[86klf300guy]

hey patsplace found the post it was roofgunners postto start i knew there was one out there-corey-

[Patsplace]

Thanks for the info. This is a basically new bike with 103 hrs. of use on it and I'm thinking that it's a minor amount of water from going through some iced over puddles and then heading back up what is right now a creek running down an old skidder trail.

I'll do the actuator check this weekend (It's flashing the 1/2 scond on, 1/2 second off pattern which means actuator) and let you know what I've found. Good tip on the dielectric grease. I've got some for a high end led flashlight that I carry (another hobby) so I can put some on the connections.

Regards,
Pat

[Roofgunner]

I'll also warn you, as I've done before in this forum-don't wash the machine with a pressure washer. I use a garden hose (we have good pressure) with one of those jet nozzles to clean mine off (almost 500 hours on it) and once a year I put it into my heated apartment/garage and detail it and do the maint. on it. This gives time to really look at things on the machine. I recently put Titan 6 ply tires (489's) and the rear tires are a little wider than the original and give it more stability. You can spray stuff like Finish 2000 (silicon), like Armoral, underneath the fenders, etc. This lessens the sticky mud from clinging. Mine is used for work so it's not a toy to me.

[Patsplace]

Yeah, I'm no fan of pressure washers on machinery. Spraying the underside of the fenders with Armourall makes sense. One of the shops in my area likes to use WD40 on the engine bits on a regular basis as an external spray, I'll let you know what I find.

[86klf300guy]

wd-40 is my choice of anti mud stickin stuff lol.we had a sprint car and we'd spray all the panels and the wing to keep the mud off and also give that just painted look high gloss under the lights lol-corey-

[kawasakimuddog]

im having the same problem you had but mine will go in and out of 4wd by its self. where can i get a shop manual at.

[Patsplace]

Howdy folks and a special Howdy to Roofgunner,

I've still got the same problem with the great flashing light mystery, considerably less than it was, but the problem is still there. It's not a biggie but it could be. When I'm coming down some stupidly steep trail that I have to wonder why I even went up it, I'm in 4 wd. Low and the engine brake feature just eats up steep descents without problem. It would be a rude situation to come to one of these and not have that engine braking business work. Could be really ugly. I always make sure it's working in those situations.

I live in an area without a Kawi shop and no one seems to know the problem. One guy from the South of the US told me what the problem was but as far as fixing it, without replacing a $300 part, no luck so far.

As it isn't a constant thing and does go away when the ignition it turned off and then back on, I'm able to live with it but like anything that isn't just "right" with your bike, it is a PO.

If anybody has any fixes (and I'm going to try the Electric Grease on the plug in connections) let me know.

By the way, put Maxxis Big Horns on the Prairie. WOW!! What a bloody difference they make. To say that I love them is a serious understatement.

[Roofgunner]

I'm going to take a shot at what the problem might be. Kawasakimuddog might have a problem with a 2wd/4wd switch causing his machine to go in and out by itself. That's a new one. Mine has never done that. I think that the flashing, due to the frequncey of it (depending on how it flashes in time, according to the manual determines whether it's the brake actuator or the front wheel drive actuator), on my BF is centered on the brake actuator mechanism. I try to use the brakes in conjunction with the brake actuator mech, rather than totally depending on it. There is probably something in the computer coupled with the brake actuator that ignites the trouble system that causes the flashing. Mine flash the freq for the brake actuator mechanism. I think that due to wear and tear that it may not work as smoothly as new and when that happens the trouble code is created which sets off the flashing. My BF appears to act normally (with 1900 miles and 503 hours) even though occasionally the lights flash. I plan on putting in a new belt even though the original seems fine---it grabs as soon as the engine speed increases. What we need regarding this is something from Kawasaki Tech services or a fix from a shop or individual when they have repaired/replaced a part or done something to totally stop the flashing signal.

[kawasakimuddog]

I Got The Flashing To Stop. I Took Out The Fuse To The Kebc And The Lights Stop Flashing. So Do I Need To Replace This Or Just Clean It Real Good

[Patsplace]

I've talked to a few Kawi shops here in BC and so far, nobody know what the problem is, but I'll keep on keeping on and go from there. Mine seems to work about the same as yours. It works but the light saying somethings wrong drives me around the bend.

I'll post any success that I have.

Regards,
Pat