I have a 2004 (made in 2003) 600 that I bought new. This winter when I installed the tracks I found that I have no FWD in reverse. I installed the reverse overide toggle switch and relay system about 6 years ago and its worked fine up until now. The relay does pull in on demand.
I checked the voltage under the hood which feeds the front Hilliard assembly and I read 6 volts AC. The system seems to engage and disengage in forward, but not reverse. Should I be getting 12v DC feeding those two little wires?

 

You might recheck the relay and wiring you installed,but the problem could also be in the plastic roller cage itself.

 

What voltage should I get when checking the feed to the front end, 12 volts? Don't want to burn it out like the fuel solenoid on my tractor..(it pulls in with 12 volt but runs on 6) Its been many years since I installed the relay and I know the relay pulls in, the hub locks up in forward on demand but not in reverse.

 

Manual says 11.8 to 12 volts to the front gear case. Check resistance also on the grey and brown /white wire case wires. Should be between 22.8-25.2 ohms resistance. You might try to jump the ground wire leading to the gear case(brown/white) to the group of grounds on the frame and see if this helps on reverse engagement. If it doesn't I'd still suspect a roller cage.

 

10-4, Got it indoors so I can work on it tomorrow.

 

Hung the bike from the rafters using the front and rear winches, then checked the grease. It still looked pristine after about four years. Checked voltage to the gearcase and found no change in voltage (11.9v) between forward and reverse so it must be in the case.
I'm going to remove the front tracks while its in the air and take it to my local mechanic next week.

 

When you said grease are you talking about the front gear case fluid?? If so and it's been 4 years and you haven't changed it do so! Uses Polaris Demand Drive Plus hub fluid.