Hello Friends,

Is anyone having problems with their 08 brutes throwing the 4x4 and engine brake actuator trouble warning? Since it was new, mine has been doing the alternating flashing 4wd 2wd at 1 second intervals. I have been able to clear the trouble by pulling the master fuse and resetting it, only to have it trip again sooner or later. I did take it back to the dealership in november, and the kid that worked there said that this was a known problem with the brutes and that neither he nor kawasaki knew what to do about it. He said that basically they just replace parts until it is either fixed or it isn't. Of course I think this kid is an idiot because, this is a safety function and after two more attemps, they are going to be giving me a new bike. Anyway, they replaced the main controller under the seat on the first attempt. Well, since then I have only ridden a couple of times and yesterday was the first time in over a month, since I have been busy moving back to PA and settling into a new job. Well, it happened again. So, I am going to find a local dealer and see what his take is. I will explain to him what has been done and what that kid said back in az. I was hoping that some of you might have had a problem and a potential fix. I am also calling kawi directly. I am not going to settle for "we'll see what happens." Its pretty scary going down a hill and having the engine brake just go away on you.

Also, does anyone know which state's lemon laws my bike would be covered under? I bought it in Az but now live in Pa. I suspect it would be Az but I don't know.

Thanks for your time.

Justin

PS I am assuming that since I haven't read about this problem here yet, that it isn't a fleet problem like that kid suggests.

After I posted this I tried some other google search strings. I did find one place that said the "bus" connector under the seat is a common problem. That is the part they replaced on mine. Then I found another site where a guy recommened bypassing the e-brake all together. Here is what he posted;

First off, check and clean the actuator connection.

You can actually just disconnect the actuator all together and get better performance and fuel mileage out of your machine. It is actually a very common mod.

There a couple ways to approach this mod.

1. Remove the fork inside the clutch cover. This disconnects the KEBC while maintaining the use of the actuator so the lights don't flash, but your actuator has to work for this one.

2. Install a DG6. This device allows a complete disconnection of the KEBC actuator and keeps the 2wd/4wd lights from flashing. With this module many guys have gone as far as ditching the Brute Force clutch cover to replace it with a simpler V-force cover and clutch parts. This makes for a very clean look and makes your machine slightly lighter. Here is a link for the DG6. http://www.diamondgracing.com/catalog/item/2034967/1653498.htm


I have the fork removed and have been very happy with the faster acceleration and lower fuel consumption. Here is a link to another thread that describes this very topic.

Don't know any thing about the BF. but as far as LEMON LAWS I know in COLORADO that ATV's are not covered by them, it would have to be checked out in each state to see if they are covered.

You might also want to read this before you get your hopes to high.

Ya just found out they aren't covered. I guess it is back to replacing parts until the warranty runs out in 3 years.

Justin

The Buss Conector problem was only a problem on early model750's ,Kawasaki issued a Technical Bullitin on this issue . I did several of the "Fixes" on 2005 Brutes. I've not heard of it on any later models.

Hmmm... well I have some faith in this new dealer/service department. They guys are older and seem more experienced/knowledgable. I bought the tools I need to troubleshoot it in accordance with the service manual to see what I find before I take it in. I really hope its solvable and not persistant because otherwise, I really love this bike.

Justin

*SIGH* so yet another problem came up today. I am taking the bike in friday to fix one or both of the actuators thats broke. But, today all of the sudden I don't have a neutral. All I did between last week and when this problem came up was unload it and park it in the garage and then load it and unload it at the trail today. Before I even got going it happened. It will go into gear but if I go back to neutral it stays in gear unless I hold the shift and let it coast. Same in reverse. It seems to me like its probably just an adjustment on the shifter, but the curious problems was then when it was in gear, she took off. Normally, she will sit there and idle in gear. I had to really hold the brakes to keep her stopped. Same thing in reverse. Additionally, every other time I had the alternating 2wd 4wd lights, the engine brake didn't work. Well now all of the sudden it does work, even with the lights flashing. So I am not sure what the heck is going on with this thing. I feel thankful that I bought that 3 year warranty. Never had an extended warranty before but something told me to get one this time. I am just praying they can work it all out because I really don't want a trouble bike for the next few years... then again who does? Wonder what they are doing for 09?

Justin

PS Other than that... she runs great! And although there isn't much anyone here can do, I appreciate you letting me whine.

can't believe the issues you are having, i only have about 300 miles on mine so far and no problems....hope the dealer takes care of you and gets everything solved, its usually just one simple problem that can cause all kinds of issues

We had a C5 vette come in with a intermittent dying problem. It ended up being loose ground wires in the harness on the back of the heads. Another shop did a heads and cam package on it and they loosened up over the last 15K miles. It would misfire and stumble etc and never threw any diagnostic codes. It was a buggar to trace down. Another one had a weird electical problem was where the A/C drain clogged and would drip down on the body control module under the passenger foot well. Then by the time it got looked at it would dry out and work fine. We caught it dripping the second or third time and cleared the evap drain.

Yes I am starting to think it might be a common problem... in the electrical system. It was just weird to me that a new problem crept up which seem to coincide with another problem "clearing"..so to speak. I love my bike and am faithful that the dealer will get it worked out. I can't take any blame though since I had problems since literally the first day.

Justin

Well dropped the beast off friday and I really got a great vibe from these guys. Everyone in the shop came over to check out the bike and give me reassurance that they would take care of it. I will keep you posted.

Justin

Yup, keep us informed. Some get ticked at me for continualy braggin' how trouble free my Kawi's are.

Well they said today that the engine brake actuator is definitely bad. So, waiting for parts. No update on the new issue yet.

Justin

Whelp, picked her up from the dealer. Says it was definitely a bad engine brake controller. When he replaced that, it cleared up the shifting problem too. As I suspected, but still don't understand, they were somehow linked. Also, when they replaced that controller, the belt light came on when they first fired it up. Said it was out of spec. So I don't know how or why that happened all of the sudden. And as a final gesture, they found a nut missing on the exhaust header. Now she is a little quieter I wish that guy hadn't rushed through my bike when he was building it on friday afternoon LOL

Justin

I hope she runs good now Justin.
It's a bummer to have defects, but it sounds like they got it taken care of.

Ya thats what I am hoping. I am not upset or bothered by it that much. As long as kawi keeps putting parts in her until 2010 I will be happy. I am not going to go off and say "kawis are junk" "never buying one again" or anything like that... I love my bike and if I have some troubles... oh well there are more important things. Besides, from everything I have read everywhere, I seem to be the only one with these multitude of issues. Just a fluke.

Justin

Good post-just keep us updated. Like said, my Kawis have been bullet-proof, but am always on the lookout for those with issues. Got to have the big picture!

yeah, keep us updated, i hate buying something new that has problems with it, I only have 325 miles on my brute, but it has been flawless and now the mods and VFJ clutch, man its fast...and talk about wheelies, even here at high altitude just stands right up in high gear with a crack of the throttle

Dave

That reminds me. I think I am going to hold off on any serious mods right now until I see if my bike is mostly trouble free for some time. I don't want to run the risk of ruining the extended warranty in case something comes up. I am still going to install new clutch springs though.

Justin

Good thinkin'!