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This is a discussion on 4x4 actuator questions within the Engine and Drivetrain forums, part of the Kawsaki Teryx Forum Technical category; Sorry guys and gals I did do a search and couldn't find answers, if these have already been answered somewhere else So Have an 08 ...
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04-29-2012, 09:50 AM
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4x4 actuator questions
Sorry guys and gals I did do a search and couldn't find answers, if these have already been answered somewhere else
So Have an 08 Teryx, and the 4wd stopped working, the diagnosis I have done so far is that the actuator feels free to move, however when flipping the switch nothing changes, you can't hear the actuator engage. At the wire I have 4.6 volts whether in 2wd or 4wd, no difference. I have tried the unit moving or stationairy. Anybody got any troubleshooting tips, what should voltage be at the actuator for each position of the switch, oh and Im running an aftermarket CDI. Thanks Walter
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08 Camo Gorilla 2" lift ITP wheels 27" Kenda Executioners Hunterworks carb kit Aftermarket CDI 
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04-29-2012, 10:39 AM
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It is vacuum operated make sure the engine is running and watch to see if is moving
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04-29-2012, 11:24 AM
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Ok so it is not moving, does that mean the vacuum device by the motor is defective, I checked hoses, and there is one hose that leads to the bottom of the front carb, and a bunch more that appear to be terminate at the frame on top of the motor, it looks like one has a one way valve on it.
Should I be able to move the vacuum piece by the motor, the actuator moves freely by the diff but I can't move the other piece.
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08 Camo Gorilla 2" lift ITP wheels 27" Kenda Executioners Hunterworks carb kit Aftermarket CDI
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04-29-2012, 01:56 PM
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2008 Teryx, Custom Creations Long Travel suspension, Cage w/doors and Exhaust, Dasa intake, Weller impellar, Dynatek CDI and Coils, K2 (Sandjunkie) Aluminum Bed, PRP seats, SDR lowered seat bases, HIDs in headlights and up top. ITP ss212s with Bighorns.
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04-29-2012, 04:54 PM
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Switch the vacume hoses on each side of the actuator there are 2 diagrams in there. Just one way to see if it's the actuator or electric switch. When you do this it should engage into 4wd.
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05-02-2012, 07:50 AM
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Well it looks like the darn cable is seized, was able to disconnect the cable and it won't move yet the vacuum actuator and the 4x4 lever on the diff move fine, so off to the store for a new cable, already tried unsiezing the stock one.
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08 Camo Gorilla 2" lift ITP wheels 27" Kenda Executioners Hunterworks carb kit Aftermarket CDI
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05-02-2012, 08:04 AM
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Note: IT'S ALL WAYS THE CABLE.
unless its not. first thing to do is unhook the little cotter pin and push the button with it running. If it moves then its the cable. 99 out if 100 times.
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Stock '09 Sport Mud Industries Snorkles Gorilla Stage One, 30" Mudzillas V-Force Mod Off-Road Windshield Off-Road Alum Top 
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05-05-2012, 03:50 AM
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Front diff cable will be next, just replaced both of mine.
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05-05-2012, 07:57 AM
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There is one thing though. You mentioned your voltage. You should only have voltage through the switch in 4wd. If you are reading voltage through the switch in 2wd as well replace the switch.
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05-13-2012, 10:36 AM
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I thought the cable was for the diffLOCK?
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2008 with 240 hours,Fundy STD Bore Kit, Muzzy Duals ,Hunterworks Carb Kit ,Dynatek C.D.I. Uni Filter ,Dalton Clutch Kit +O.D. Cover ,Kolpin Dual Gun Holders ,Warn XT 3000 Wireless Winch ,TYRI L.E.D. Lights,Custom 500 Watt Stereo ,Custom Cut Lexan Windshields , Full Guages and 28 inch Maxxis Mudzillas Soon to fab 4 seater with boat rack
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08-29-2012, 11:34 AM
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Well i have been dealing with my Teryx going into 4x4 but not wanting to come out. So i started checking things out and figured out that the cable was stuck but also the actuator ifyou push 4x4 it will push the rode but the when switched back it want pull the rod. So im having trouble with both and i need help finding an actuator.
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2008 FCP Teryx 840 with Spray Team Gorilla Axle Betsill # 77
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08-29-2012, 02:53 PM
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i was just working on mine. It engages but does not want to release. The cables is clean but I can feel resistance so I would say it needs a new one. I rigged up another spring by the lever on the diff to help pull it back to 2wd untill I can get a cable.
In my experiance with many years of working on boats is that lubing it really doesnt work and if it does then not for long. Just replace it
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