Ok. So all winter the awd was finicky in the cold. This spring it doesn't seem to work at all. I opened up the hubs to inspect and do an oil change. This is my first time doing this job. To my knowledge every thing looked ok. I tested the electromagnet with the armature plate and got no reaction. I've read or watched fixes that involve grounding issues or pole tolerances being off. What is the most likely issue in these cases.

 

Also the awd light works in reverse but does not come on in forward. The Speedo has never worked since I've owned the bike but the back light on the instrument panel does.

 

The armature plates may be warped or worn too, but it sounds like a grounding problem. Tie the hub ground wires in to a good ground. Does the 4WD kick in in low or high if you push the reverse override button?

 

Today I jacked it up. All 4 wheels off the ground. No awd on the front when in reverse. The override limiter works on the back wheels. When I pulled the hubs there was some pretty nasty oil on one side. The other was almost empty. Was able to fill the left side. I stripped the little magnet fill screw on the right side. I'm tracking down a new hub case so it will have to wait. I'm trying to hold off on the ground bypass until the end and I checked every other option. If the hall effect speed sensor is bad would that kill the awd? I went all winter with out it working and still had awd. Could it have kept the ground circuit and then just crap the bed all the way. I intend to replace the sensor regardless.

 

I thought everything looked okay in the hubs? I'm not sure but I don't think the Hall effect sensor affects anything except the speedometer/odometer reading. On some old ATVs the speedometer has to work for the 4WD to work, but I don't know if yours is one of them. If it is and the speedometer itself is broken, it can be bypassed so you don't need to buy a new one.

P.S. If the sensor is covered with mud that could be enough to make it quit working.

 

When I say everything looks ok it's that I don't see any apparent damage. All the bearings roll fine. There is some wear marks on the armature plates that I would think is normal. They aren't bent up. All the info I've come across says that polaris went with a sigital

 

[QUOTE=Kyle46&2;3393379]When I say everything looks ok it's that I don't see any apparent damage. All the bearings roll fine. There is some wear marks on the armature plates that I would think is normal. They aren't bent up. All the info I've come across says that polaris went with a digital speedometer in 00. The hall effect sensor runs up into the speedometer cluster. I have yet to find anyone saying that fixing it repaired the awd. Guess I'm hoping for an easy fix.