I just purchased a 2007 polaris sportsman 500 efi. The issue I am having is that while driving in 2wd, every once in a while it feels like the front AWD engages by itself. At speeds it can feel like the front brakes apply.

The front differential was taken out and sent to the dealer. They reported that it was fine internally. I confirmed this with dealer. Today while cleaning it, I noticed a broken wire, that lead to the front differential. It was grey and was part of a four wire connection. I temporarily tied it together and the bike seemed to work fine after that. Could that have been the issue?

 

Grey is the main power wire to the front diff. Could be the problem or still could be an adc clutch pack or roll cage that could be grabbing even in two wheel drive mode.Several complaints on this.Dirt Cheap Yamaha, Honda & Polaris OEM Parts & Accessories – Cycle Parts Warehouse