I have a 2003 Polaris sportsman 600. AWD works in forward but not reverse. Speedo works. AWD light comes on when override button is pushed. Shows reverse on pod. Any ideas?

 

If you've changed fluid recently,just splice a wire into the brown/white wire(ground) on the front diff to a good ground such as the coil mount or a good bare frame ground and see if the awd works then in reverse. If it doesn't you can try the reverse over ride "mod" this guy did and see if it helps.




"Reverse override mod"

Polaris has incorporated a safety feature on all their 4wd models. This feature, which is operational all the time when reverse is selected, will limited engine power and cut out the front wheel drive unless you push the "override" button.

One of the main reasons you would want to do this mod is because when you get stuck and the only way out is reverse, it is impossible to pull the ATV backwards while applying throttle AND pushing the override button. It is also very helpful when you use your ATV to plow and need 4wd every time you back up with the weight of the plow hanging off the front.

This mod will give you 4wd and full power when in reverse without having to push the override button. This is for all Polaris Sportsman models with the new style Speedo (2003) and Sp700, 02. Continue down below for pre 03 model instructions.

The problem with the new style, is that the function button for the Speedo is combined with the override button and it is not as straight forward as the old style Speedo. Doing it this way everything works as it should exactly the way it did before the mod.

The nicest thing about this mod is that you do not need to cut any wires or drill any holes.

You will need to purchase a standard 4 pin, 12v relay, 4 pieces of 16 gauge wire about 8" long, 4 female crimp on spade connectors (for connection of wires to relay), and 4 wire splice connectors. (they are usually blue and you simply insert the wires and squeeze with pliers, then fold back the protective locking cover)

Open the pod and locate the wiring harness coming from the Speedo.

Relay terminal #30 connect to Polaris brown wire
Relay terminal #87 connect to Polaris wire gray/orange
Relay terminal #86 connect to Polaris wire red/white
Relay terminal #85 connect to Polaris wire purple.

Use dielectric grease at all electrical connections to prevent corrosion in the long run or even better, liquid tape.

To test, simply put it in reverse with the engine running, if the Speedo flashes the word "SLOW" (just like it did before the mod, when you pressed the override button) you did everything correct."

If none of this works,the problem could be internal such as a cracked roller cage in the front differential that's allowing awd in forward,but not in reverse.

 

I will try the fluid first then the splice.

 

Changed the fluid seem to work more, then splice br/w to gnd and it worked about 50% of the time. Not sure about the relay fix, I'm a little unsure of what goes where.

 

Might be time to check into the front diff if operation is sporadic and any electrical problem has been eliminated. Best to have a manual if you don't have one.2003 Polaris Sportsman 600 Service Manual PDF Download