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I recently aquired a 2003 Polaris Sportsman 600 and the front end will not engage in either Low or high AWD with the rear end jacked up and free from the ground. The AWD indicator lights up and the switch appears to be OK. However the front end will engage in reverse with the Yellow reverse override switch depressed. I suspect an electrical problem, but don't know where to look. Any help will be greatly appreciated. Thank you. laskeno7@msn.com

 

Afternoon minkman
I'm not sure bout the 03 models if they have the Hilliard front trans., I know with my 06 500 X-2 the back wheels have to turn/slip 1/5 of a turn to engage. And when they do engage I can't feel it, It's just there, As for holding the yellow button in, in reverse, That over rides everything and is in 4wd,

 

if u have a pod u should have diagnostic mode to check switch. should engage if reverse goes in but sounds electrical is fluid good in front diff?

 

I checked the AWD switch and it is working along with indicator LED. And I just changed the front and rear gearboxes with Polaris synthetic lube along with the transmision with Polaris synthetic lube. A local Polaris dealer told me to check the transmission gear selector switch on the side of the transmission, but without a electrical schematic I have no clue what to check. I was told there is about a 20 step process to check the electrical system as the speedometer is suppose to be part of the AWD engagement. Thanks for all your help.