My speedometer is busted and does not work, neither does the AWD. The AWD light does NOT come on, and I have the brown/white and brown wires that go to the speedometer wired together. Is there a hot wire going to the AWD system? Does anybody have a wiring diagram showing how to Hotwire this?
Thanks a lot

 

If the AWD indicator light bulb is burnt out the awd will not work. The bulb itself is part of the awd operation as crazy as it sounds.

Here's the video to re-check you done it right, but sounds like you did it ok. Can,t hurt to make sure though.

 

Thanks for the response TLC. Can I jump across the bulb to test and see if its working? This is the silliest design I have ever seen..

 

Bulb is internal on 99 models and up with the slide type switch and bulb burn out(and not replaceable) which didn't happen often wasn't supposed to interfere with awd mode as they added a diode across these two wires in the harness to the speedo,BUT they didn't allow for speedos going out taking the awd with it also. Wiring to the bulb area is the same as the wires to the speedo and awd coils. Grey and brown/white.Grey is the hot wire. You can use a sharp pointed test light to see if the grey wire is hot,but may not have a good ground in the brown/white wire. You can try jumping the brown/white wire to a good ground(brown) at the switch and see if the awd lights up and awd becomes active.If it doesn't, some have just grounded the brown/white wire from the speedo if the speedo was already trashed out just to get awd function OR as in the case of this video they just made a common new ground for the brown/white wires leading to each hub coil to either the frame or a group of brown wires. Hopefully if you make a common ground the light will come on and the awd will work. http://www.cyclepartswarehouse.com/f...2002&fveh=5583
Here's cheap 5 buck pdf service manual that has the wiring schematic.http://polaris-atv.brssm.com/2002-Po...ce-Manual.html

 

Would this have the Hillard clutch in the hubs? If so, could I hardwire a switch to them so I can control when it's on?

 

You have the awd system in the hubs. Problem wasn't the hot wiring going to the strut coils,but grounding problems either through broken speedos on the 2000 and later models or even if the speedo is good, just simply loosing a good ground connection from the awd switch to the speedo,then to the strut coils.This long grounding path can cause interruptions.Not necessary to run a separate switch when all you have to do is insure you have a good ground path through one of the methods above. Just jack the machine up,tires off the ground to test,tie another ground wire into the brown/white and brown you already have tied together at the speedo to a good frame ground and see if it fixes the awd problem.If it doesn't just do as the video shows about making a new common ground directly from the coil ground wires themselves.That is if you don't want to invest in a new speedo that may not always solve this thin wire grounding issue.

 

At one time Polaris did have a better set up. My dads 1997 SP500 has the cable operated speedo.
One time we rolled it down a hill and smashed the whole pod off, speedo , headlight and all yet the awd still worked like normal.
Another strange thing is all Polaris awd systems work the same yet some Polaris 4x4 did not even have a speedo at all. like the Magnum 325 4X4.
Then some Einstein at Polaris decided to make a $300 speedo part of the AWD operation.

 

Could you use the AWD control module off the older model?

 

Old Polaris Tech, two wires coming from the hub itself, the grey is hot and the other one is ground correct? So if I put 12 volts to these wires, the AWD should come on correct? Sorry about all of the questions, I have never messed with a system such as this one. Thanks a lot

 

Why? Had more problems with this awd switch that the bulb had to work or the circuit was broken. The change to the sliding led switch was a better move. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse