I have spent hours reading this forum in an attempt to find an answer, but nothing. I have a 2000 scrambler 500 4x4. When I slide the AWD switch over the light comes on, but no 4wd. I have power to the wires for the hubs & continuity. Hubs clean w/fresh oil & proper level. New armature plates but when I took it apart for the fifth time I did NOT see if the Armature pltes held to the hub when power was on.. I should also say that I just noticed that when I was reversing there was no need to use the rev. overide. The rev limiter for reverse is not working. A few times when I would put it in Rev it would die. I would need to hold the overide button in to put it into rev. If I am in Rev & push the overide button the AWD light does come on. Could the gear seletor switch be the problem or relay or ?.

 

Any updates on this? I am in the same boat.

 

If the thin black plate with the three tabs is bent at all, even a little bit, it wont engage. That happened to my 99 scrambler. There should be two wear rings/grooves in that plate where it makes contact with the electro-magnet. I had mine apart twice before I saw it. Let us know.

 

How about this. Today I go out and hookup my scrambler to my jetski trailer in the back yard. I pull it to the front yard in awd, worked well. All 4 tires spun together a few times. I shut it off in the front yard to do some other work for awhile. Unhook the trailer start it up and pull away. It was still in awd when I shut it off. When I pulled away the awd did not work at all. I spun around on it for a little while trying to get the awd to work but nothing.?? What would cause both hubs to stop working at the same time? I got it back into the garage and the awd light was not on at the switch. My neutral and reverse lights worked fine. I unplugged the trans switch and still nothing. I shut the door and went to work. Any Idea's?

 

Sounds like trans switch, find a place on the circuit board under the front cover that has 12 volts to it with the key on, you may have to build a wire that will go from 1 to 2 spade terminals, hook the hub wires to this , should make awd work and switch on handlebar will turn it on and off.

 

Thanks for the response. I will look into this this morning.--Dave

 

Make sure there is no play in the hubs+fluid in there.........

 

In the last week I had gone throught the hubs and cleaned everything and changed the oil. They were reassembled like new when I was done.

Update!-- today i plugged the trans switch back in and turned the key on and suprise the awd light was back on. I wiggled the shifter and the light goes off. I push harder forward on the shifter and the light comes back on. Is this telling me I have a bad/going trans switch?