today while out riding i noticed my awd light was out, when i stopped i was messing with the gear selector and i had to hold it all the way forward while in high to get my awd and awd light to work, never give me any problems before and the machine shifts great as a mateer of fact it just came ffom a tune-up at the shop, has anyone experienced this before

 

That happened a lot on the early machines. Order and install a new switch. They updated to a better design.

 

<div class="FTQUOTE"><begin quote>Originally posted by: 94harley

That happened a lot on the early machines. Order and install a new switch. They updated to a better design.</end quote></div>

Before buying a new switch (they cost almost $100), what year is it? It may just be that the gear selector "lid" is loose. Make sure that the top of the gear selector is bolted down tight. If not, tighten it.

Look at this post and see if it helps:
http://forums.atvconnection.co...tid=11&threadid=558603

Same problem, didn't cost me a penny to fix it.

 

it's a 96 xplorer 400,where is the switch located in the gear selector box or you talking about the awd drive switch on the handlebar

 

<div class="FTQUOTE"><begin quote>Originally posted by: pipelinewelder20

it's a 96 xplorer 400,where is the switch located in the gear selector box or you talking about the awd drive switch on the handlebar</end quote></div>

It is in the gear selector box. It is called the "transmission switch", and I am pretty sure your model is similar to mine. Did you look at the link that I posted above? There is a picture and a pretty good description of the problem I had and how I solved it.

Take a look at that and post back here with any questions or progress.