Have a buddy whose '04 sportsman 700 AWD does not work properly. It is intermittent, will start working and then quit on him. Has had it to a few dealers and after spending some good coin, he still has the same problem. Supposedly all the wiring has been checked to magnets many times and the AWD switch has been verified. Not much else except the instrument cluster. Could this be the problem? Any help would be appreciated.

 

Has anyone cracked into front gearcase and checked roll cage for damage?