Well OPT,hope you read this,and hope you recall my other posts about the awd trouble I am having with my 04 sportsman 400?
I have tried everything,except the re-grounding trick to get the right front to spin in awd.
Pulled it all apart(again),cleaned it all even thought it was spotless,checked clutch by hand,again!!!!!
Turning clutch by hand the rollers ride up the ramps pretty well to the tops,what else is there besides an Exercism?
Do you think re-grounding the wire in the pod would help even though one wheel works?
Your thoughts would be great on this!!!!!

 

Try grounding the brown wires like this guy did on a Sportsman 500 and see if it solves the problem. If it doesn't,then you can try the speedo pod harness bypass. If none of this works then the problem could still be mechanical especially if you're getting 12 volts on the strut coil hot wire.

 

I was reluctant to start cutting wires,but now have nothing to lose so will give it a try.
You say it could still be mechanical,could you elaborate?Everything seems to be working as it should.

 

A lot of people over look the inner pole that's machined into the strut. If ground down could affect plate attachment to coil and the strut assy would have to be replaced.Face of the hub seal sleeve must be flush with the inner pole(no more than .001 gap),rare but have had problems in the hubs themselves. Had one guy that had the three welds break on the inside of the hub and it just spun,but I think we discussed all this and also since you said you've been through this several times.

 

Well every little bit of info helps.I think I will give the ground jumper a try next,if that dont work I will tear the hub apart again and see if there is something I missed,although it is a straight forward set-up.Had nothin' else to do on Sunday anyway.
wish me luck,lol

 

...and one more thing,this might be a dumb one,
I have my quad on axle stands,should the front prop shaft and cv axles turn all the time,both with awd switch on and off?
Mine do and I was wondering if this is correct.If not correct what would the problem be?
But I am thinking they should,at least I hope they should because I dont need another problem with my machine!

 

On the ground and in non awd mode or even in awd the drive shafts turn at the same speed as the tires as long as the ignition is off..While jacked up the front shafts will turn along with the prop shaft if you turn the rear tires. They're just "free wheeling" as they call it until the awd in the hubs kick in. Sometimes when you have all wheels off the ground you can have a "partial or false lock" in neutral or in gear when you turn the rear tires and one hub will lock up. Usually just turning the rear wheels backward then forwards unlocks this hub.

 

So even when jacked up,engine running ,in gear,giving some throttle,everything spins,front and back,with or without awd on?

 

Front tires should turn only when the awd is switched on. Occasionally you'll have one front wheel that will try to turn,but if the system is working right you should be able to stop it with your foot. In awd mode both should engage and you can't stop them.Again only if the awd is working properly.

 

Thanks again for all you help.
I was reading through almost every post on here regarding the awd system,and in one you said when the awd is on the coil pulls the armature plate "away" from the clutch.Not to question your expertise on these Polaris machines,we all know it is vast and helpful,but its my understanding that when the coil is energized the plate and clutch lock together(becoming one sort of)thus causing the rollers to ramp up and clamp the hub because the coil holds the plate.Am I right in saying this,or is my understanding of the system way off.Again,far be it for me to question you,I just want to fully understand it all so I can sort out my problem.