Just some history on the bike.
I bought a 95 sportsman that didn't run. Cleaned carb, new battery, fixed recoil starter, fixed a stuck brush in the starter and it runs good.

I was plowing my driveway and I noticed that the AWD was not working, so looked in repair manual and first place to start is the bulb. Reading on the forums it seems the bulb is needed to transfer power to the hubs on the older models.

Ok first problem is the bulb seems to be discontinued. The part number is 4030047. Does anyone know where to get this bulb? I tried eBay, online parts, and local dealer(no Help).

I have replaced 2 headlights and 3 indicator bulbs. Previous owner must have ran it with bad battery from what I have read.

I could not have gotten this far without these forums, a lot of good info here!

Brian

 

Most good dealers should still stock these. A lot of online places don't any more. Worst case try to see if you can match it up at an auto supply.

 

Can you post a picture of the bulb ? I'm sure there's a cross reference to it in one of my industrial catalogs .

 

Looking at the wiring diagram for a 95 Sportsman shows the awd light is for indication only , it shouldn't effect the operation of the awd , the wiring diagram shows it in parallel with the front hub coils . So any 12 volt lamp that will fit in the socket should work for you .

 

Very small blue bulb that has a thin wire at the back of the base that completes the circuit. Unscrew the awd indicator assembly from the throttle housing and the bulb comes out with a small slotted screw driver. Worst case scenario if you can't find this bulb, you can try jumping the gray and gray/white wires together down from the awd indicator and see if you then have awd.Haven't done it myself,but have heard of others trying this.

 

Yes sir that is the bulb. I have tried local auto parts, and industrial supply (McMaster-Carr and Grainger). I will give a call to a few other Polaris dealers, I just hate to run 20+ miles for a $4 bulb

I will look into jumping those wires tomorrow.

Yooper I'll check out the wire diagram, I was just going off other post's that say you need the bulb in circuit to work.

Thanks for the help guys!

 

my 95 xpolrer only had 1 good bulb (neutral lite) wonder y they all burn out, anyway auto zone has 2 paks of a 1.3 watt mini buld that I clipped the wires loose and straightened out, stuck them in the old lite base bent them over like the old buld was and put it in, works fine so far, bulb is bigger but still fits in the hole. the switch on the shifter is most likely y the 4x4 wont work. i bypassed the shifter switch at the circuit board, moved the gray power wire from the AWD switch over to the red/white blades in the center of the circuit board.

 

I know this thread is a few years late but my AWD light won't come on either. All four tires seem to work but I'm not sure how to make sure. Does the light have to work for the awd to engage or is the light purely an indicator only?

 

The light is a indicator only . { that's why your awd isn't affected by the light being burned out }

 

Yes,after the 93 or 94 models(can't remember which) the awd bulb was an indicator only. Before those years the bulb was part of the awd circuitry and if the bulb burnt out you'd lose awd which was kinda stupid.