2004 sportsman 400
#11
Yes,yours is the 400 and may have brown wires leading to the hubs,but you can try to reground and see if it helps. If this doesn't work try the speedo harness wiring.Don't have the schematic on the 400,but if it doesn't have the brown/wire wire in the harness,just jumper brown to another brown or to a good frame mount and see if you have awd.
#14
...and for now I will leave you for tonite until I can actually get my hands dirty on the machine and do some fact gathering and troubleshooting,but I am sure I will be back within a couple of days to bend your ear for more free advice and expertise
thanks again OPT
thanks again OPT
#15
Hello again OPT,its been a few days so I hope you are still following me!
After some investigation heres where I stand and hope its not confusing.
1.Speedo not working but lcd display is perfect
2.I have 3 wheel drive,right front not working,but axel does spin so I can presume its not a drive line problem
3.13.1 volts @ plug going to right hub
4.The two wires gong to hub are very thin type,one is greyish white,the other is brown with white strip
5.I put my meter on the 2 wires and got 26.8 ohms(meter on lowest setting
So can you give me any idea as to why that wheel is not engaging?
My thoughts were a bad coil but I didnt pull the wheel yet to check the actual coil.
The last time I replaced bearings and seal on that wheel I also replaced the armature plate and it did seem to "stick" to the coil pretty good.
Could it be over tourqe on castle nut,I have no tourque wrench?
Also when I was looking around under the front plastic I noticed an unused plug,it has a brown wire and a purple w/white stripe wire,I assume its for another model using the same harness,would I be right?
Well I hope this helps in figureing it out for me,I am stumped!!!!!
After some investigation heres where I stand and hope its not confusing.
1.Speedo not working but lcd display is perfect
2.I have 3 wheel drive,right front not working,but axel does spin so I can presume its not a drive line problem
3.13.1 volts @ plug going to right hub
4.The two wires gong to hub are very thin type,one is greyish white,the other is brown with white strip
5.I put my meter on the 2 wires and got 26.8 ohms(meter on lowest setting
So can you give me any idea as to why that wheel is not engaging?
My thoughts were a bad coil but I didnt pull the wheel yet to check the actual coil.
The last time I replaced bearings and seal on that wheel I also replaced the armature plate and it did seem to "stick" to the coil pretty good.
Could it be over tourqe on castle nut,I have no tourque wrench?
Also when I was looking around under the front plastic I noticed an unused plug,it has a brown wire and a purple w/white stripe wire,I assume its for another model using the same harness,would I be right?
Well I hope this helps in figureing it out for me,I am stumped!!!!!
#17
If you have voltage going to the hub coil then sounds like you could have a mechanical problem. I'd pull the hub off,check the roll cage operation along with checking again that the armature plate isn't worn and is also pulling to the coil when in gear and the awd switch is on.Too much torque can affect the awd operation,warp the armature plate,etc. Hub nut torque is 12 foot pounds. Harbor Freight,Northern Tool has cheap torque wrenches that are a must for tool boxes.Plus if you have the display showing but no speed or mileage accumulation,could be the hall effect sensor posted about earlier if you haven't replaced it yet..
#18
Would a faulty Hall Effect sensor cause awd trouble,after all I am getting voltage.Hopefully tomorrow I will get the time to pull the wheel off and tear into the hub again.I should add that about 8 months ago I had the bearing destroy itself on that wheel and the axle dropped causing severe damage to spindle.The hub went dry.This all happen before I know as much as I do now about the awd system on this quad.this also caused some gauling of hub strut,but it was on inboard side of seal and it didnt seem to do damge to the coil.I used a dremel to grind down the hub strut,cleaned everything real well,new seals,bearings and armature plate.The Hilliard clutch looked fine,some small black staining,but I cleaned it like a doctors office.I even soaked the garter spring being careful not to stretch it.But now I am wondering if the excessive heat caused damage to the coil.I believe I read somewhere that you should get 12 volts over both poles of the coil itself,is this right?(By that I mean the actual surfaces where the armature plate rides,this electrical is still a little over my head but slowly learning)
....would a faulty hall effect sensor cause just on wheel not to engage?
....would a faulty hall effect sensor cause just on wheel not to engage?
#19
....also how do I check the roll cage operation if the hub is off,do you mean just by hand,because wouldnt it not be wise to put into gear if the hub and castle nut are off(dumb question I know but....lol)


