2004 polaris sportsman 500 awd.

i have a problem with the awd lockin in reverse. the back tires will spin but the front tires wont. i have the override button pushed in and the indecator shows its in awd but no front wheel spin. PLEASE HELP!!!

 

Welcome to the forum! Both front wheels not engaging or maybe just one? Pull the front cover and check that both the small connectors for the the awd are connected and with the key on,in gear and awd on check that you have 12 volts with a test light on each gray wire in the connector harness. Place the transmission in reverse and over ride button pushed in,then check for voltage again. If you have voltage then could be problems in the hubs,but not usually both at the same time! If speedo shows you are in reverse (then transmissions switches are ok). Shows also on the wiring diagram that I have on the 04 model the over ride went through the speedometer as an indicator and to complete the circuit. If you don't have power on the gray awd wires in reverse the problem could be in the speedo. Others may have had this problem and may help. Didn't have this problem at the shop far as I could remember. OPT

 

I checked the voltage and it had power in reverse with the override pushed in but still no wheel spin. ive read that you can splice some wire in the speedo to ground it off better since it is grounded through the speedo. i would hate to have to spend alot of money to send it to a shop or buy a new speedo.

 

If you have the centralized awd and not the awd in the hubs, it could be a plastic roll cage issue in the front differential. Depending on which model 2004 Sportsman 500 you have. They had both systems that year. OPT

 

i do believe it has the centralized awd system. its very annoying. i got stuck just trying to back up a small incline.

 

If you have power to the front gear case in reverse and the awd wont engage when the rear wheels slip then it's possible you have a roll cage problem. There are several posts on the plastic roll cage problems. OPT