I am having an issue with my 1999 335 Polaris Sportsman. The AWD works intermittently when I have the button pushed in on the handlebars and the indicator light comes on. It does it forward and reverse. I have been stuck and the rear wheels will spin then after a while the AWD will kick in and work. It will work for a while then stop working. What can I check for a fix to this problem. Thank-you.

 

Try this first.

 

The wires I look for in the wiring/ fuse panel under the front rack are the same for the 335 as they are for the 500?

 

Same type gray and brown wires in two connectors.

 

I have a brown wire with a white stripe that is with the grey wire coming from the front hubs. Is this the same in the video? The wires go to the circuit panel where another brown wire with a white stripe goes to a black box. Is the brown wire with a white stripe the ground?

 

Just trace the awd ground wires(brown or brown/white as they changed over the years) from each side of the struts,jump a larger wire from them to ground. Try it on the terminal board first. If that doesn't help just jump them to a good ground area such as the coil mount bolt. Plus jump the brown/white in the speedo connector to either a brown(ground) wire in the connector or to a good frame ground. This bypasses the awd ground circuit from going through the speedo. If you need a good wiring diagram for your model here's a good manual.http://visit.tradebit.com/visit.php/...75/264163829/9

 

Thank-you for the information. I tried the AWD before I grounded the 2 brown / white wires from each hub to the mounting bolt on the coil and it was working this time. Could low voltage or charge in the battery causing this intermittent AWD problem. I tried the bike in 4x4 a few times today both in forward and reverse and it seems to be working. Also, my speedometer hasn't been working for sometime either and you mentioned that the AWD ground is tied to the speedometer. This maybe part of the problem too.

 

Broken speedos are one way ground paths are lost on awd function.. Either replacing the expensive speedo or jumping the brown/white wire to a brown or frame ground usually helps. When it doesn't help on jumping the speedo wires,the ground may be lost from the speedo to the hubs because of the long run the wires have to make along with how thin they are to begin with. That's how jumping to a larger wire and to a better frame ground helps. Hope the regrounding holds up for you.

 

I hope it holds too. Thank-you for your advice.