I have a 2003 Sportsman 600 and have positively confirmed that the Demand4Drive works in both Reverse (w/speed override button) and in Low gear forward...... but in High gear the AWD doesn't kick in.... only the rear wheels spin in High Gear when they break loose. Any suggestions for things to check would be appreciated. Thanks!

 

Make sure the gear position switch on the gear case is working correctly. Should be showing correct gear position on the speedo. If it is ok,then with the key on, awd button engaged and in gear,check with a test light or volt meter that the hot wire leading to the front differential has power. If it does,then it could be a roll cage issue in the front diff. Awd may work in reverse,but if the cage is cracked,it may not work in forward range. IF it doesn't have power,could be grounding issue. The awd ground circuit goes through the speedo and then to the diff. On the speedo harness jump the brown/white(awd ground wire) to the brown(common ground) and then see if the diff has power in forward range.Plus not a bad idea to check the awd coil resistance. Should show between 22.8-25 ohms resistance between the grey and brown/white wires.

 

Well the AWD does work in Low gear forward, so I'm guessing (at this point) that this is an electrical issue related to something other than the cage. Again, the AWD works in Reverse and Low gear...... but not in High gear. Thanks for taking the time to respond!