I just got back from hunting and my 08 sportsman 500 EFI seemed to have intermittent 4 wheel drive. It has the ADC (automatic descent control). With the switch in 4x4 there were times when it definatly was not working, yet other times it seemed that is was working, but only after I would switch it out of 4x4 then back in.

Question; How to best start trouble shooting this? Step 1 check? step 2 check ? step 3 check? and so on. I tend to think it is a switch problem but really don't have any good idea.

I plan to put it on a lift sunday and start trying to isolate what the problem is. with the switch in 4x4 the front drive shaft turns. after that I don't know where to start, and would like suggestions on the best logical steps to troubleshoot it.

Thanks for any help.

P.S. My 14 yr old got his first deer this trip.

 

You're just going to have to check the switch wiring out all the way to the gear case wiring to make sure you have power,could be just a ground problem OR may not even be an electrical problem,but an internal gear case problem (cage problem,armature plate,etc?) Cheap old test light or ohm meter the best way.Just start tracing the wires into the harness,eliminating one at a time,plus check the electrical connector at the gear case. OPT

 

Congrats on your boy's first deer

 

I put it up on a lift this afternoon and got a little spin on the front wheels in 4wd. when i gave the front wheel some resistance with my hand i could stop the front wheel. the front drive shaft is turning into the front diff.

when i put my 400 sportsman on the lift and did the same exeriment, i got definate spin on the front wheel and i could not stop it with my hand. definate power to the front wheels.

so, i think i have a bigger problem with it than i thought i did. basically not getting any power from the diff to the front axels, looks like i am getting power from the driveshaft into the front diff.

any other suggestions on how to proceed? when people use the the term 'front cage', are they reffering to the front diff?

 

"cage" is referring to the hilliard roller cage that when turns,ramps up and locks the front wheel drive to where the front wheels pull when needed and disengage when the rear wheels can carry the load. If the cage is broken(a common problem) or armature plate warped,or a combination of both then front wheel drive won't engage.If you have power going in to the font gear case,then probably need to tear down and inspect for damage.Replacement aluminum cages are offered through Polaris instead of the plastic cages OR other members can give you other makes of cages they have used. OPT

 

your front drive shaft will always turn when the rear tires turn. It's the components involved with the front drive that engage/disengage 4x4. First check your electrical to verify power to the front drive. If that checks out OK you may need to tear apart the front drive and look at the internal components, sprague carrier/(aka cage) and plate etc. The cages are known for failure over time or abuse. If your cage is busted you can use John Deere parts which are much cheaper than Polaris or go with an aftermarket aluminum sprague which would hold up alot better but there is debate among some as to whether or not you'll end up breaking something else next time. Only as strong as the weakest link thing.

 

Doh! you beat me to it. But your answer is acceptable as well. LOL