[Fishstyx]

Hi all,

Does anyone here have a good grasp of how the electric front differential works because I seem to have screwed mine up.

Normal operation, push the 4WD button, a short motor noise
push front diff lock button and another motor noise.
reverse the sequence and the motor reverses.

I was trying to test my fan relay but instead jumpered my front diff relay (I recognized the sound of the diff motor). Now when I push the 4WD button, no sound. I'm not sure what state the diff is in or how to reset it so the buttons work.

[NMKawierider]

Assuming you mean the Z Force 800-either trail or EX, we have a wiring diagram in that section for them. From what I see and understand the one drive motor has two stages, moving one slide forked to first couple the carrier to the pinion power, then it slides a little farther to lock the carrier to one axle which nulls the spider gears locking the other axle to the carrier...accentually. I assume the relays just send power to the motor and some kind of "pot" to determine position and they or it can be damaged if shorted or powered out of sequence. If the switch and relays check out, I am guessing you may be replacing an actuator. Fortunately CFM's actuators are cheap..unlike others that can cost hundreds.     

[Fishstyx]

Fixed it. There are two relays, one moved the actuator one direction, the other in reverse. I manually activated the reverse relay to move the actuator back where it should be and whala, which means, 'and then I figured it out'.

It's still frustrating that fan relay isn't where the shop manual says it should be.

[NMKawierider]

Fixed it. There are two relays, one moved the actuator one direction, the other in reverse. I manually activated the reverse relay to move the actuator back where it should be and whala, which means, 'and then I figured it out'.

It's still frustrating that fan relay isn't where the shop manual says it should be.

A quick fan relay test would be - pull the connector off the fan switch(aka thermoswitch) which is on the right side of the radiator and jumper the two pins on the harness side with the key on. If the relay is OK, the fan will come on. If not...it won't.

Yeah found that out about the relay myself a while back. It's in there with the rest but not in the same order. Have to look at load wire colors.

[Fishstyx]

A quick fan relay test would be - pull the connector off the fan switch(aka thermoswitch) which is on the right side of the radiator and jumper the two pins on the harness side with the key on. If the relay is OK, the fan will come on. If not...it won't.

Yeah found that out about the relay myself a while back. It's in there with the rest but not in the same order. Have to look at load wire colors.

Did that and the fan came on. I bought a new CFMoto thermos switch from the local dealer, but it has a different (round) connector. Mine is oval.

[NMKawierider]

A quick fan relay test would be - pull the connector off the fan switch(aka thermoswitch) which is on the right side of the radiator and jumper the two pins on the harness side with the key on. If the relay is OK, the fan will come on. If not...it won't.

Yeah found that out about the relay myself a while back. It's in there with the rest but not in the same order. Have to look at load wire colors.

Did that and the fan came on. I bought a new CFMoto thermos switch from the local dealer, but it has a different (round) connector. Mine is oval.

Yeah..that's a problem. I always though if mine ever went out I would just get a Polaris fan switch...one with a pigtail..and make my own new connections. Just never confirmed the size and thread. Maybe not this exact one but one like it.

https://www.amazon.com/Caltric-COOLING-RADIATOR-SPORTSMAN-2000-2003/dp/B01BSJ3COM/ref=sr_1_5?keywords=Polaris+fan+switch&qid=1555889484&s=gateway&sr=8-5