I just bought a 2004 Polaris sportsman 500. The first time I took it out it ran great, but the first mudhole I went through I got stuck and realized the AWD didn't engage. The drive shaft is spinning to the front end and the axle is turning to the right front hub. I checked all the fluids and they were all clean. I understand there is a magnetic system that engages the awd at the hub. Is that correct? I took the cover off the front below the headlight and checked the wires to the hub for voltage with the quad on a lift in gear and in AWD mode and got nothing. I don't know what else to do. Also I noticed a plug at the hub about 1/4" with an allen head, I looked in the manual to see what kind of fluid to put in there but I didn't see anything on that. Trying to avoid getting raped at the dealer , so any help would be greatly appreciated. Thanks!!

 

That 1/4" allen plug is where you full the front hub. Use ONLY "Polaris demand drive fluid" in there the dealer sells this fluid in 1Ltr jugs you only need about 2 or 3oz. I would start by changing the fluid. Try a search on this subject there is latterly 100`s of questions and answers.

 

Also put the quad in reverse. Then in forward. That will help it to connect and also to disconnect when you need to. Forward and the backwards or vise versa. Follow the wires also until you find the problem with your electrical probe. Fluid must be very clean for it to operate correctly. And by forward and reverse and vice versa method you will be ok.

 

I had one the other day that had conection problem in side handle switch on right side, I noticed if i would wiggle awd switch the awd would light up sometimes So took apart and cleaned top half of switch an Bingo fix the problem with that atv...