Recently picked this machine up and the 4wd worked then a few days ago it no longer works, when switch is flipped it shows up that 4wd is locked in but front tire/tires are still free moving?

 

First off change the hub fluid .Use Polaris Demand Drive hub fluid only. Check for any leakage around the inner hubs or struts. Easiest way to tell on awd is to jack the machine up,all 4 tires off the ground. In awd you can see if either wheel is engaged. If both are not turning check that the connectors under the front panel are ok and that you have 12 volts to the grey wires running down to each strut with key on,in gear,awd engaged. Brown wire is ground. If the awd switch lights up plus have 12 volts to the grey wires,just run a jump wire from the brown wires to the main grounding area of the coil and see if awd works then. If it still doesn't,could be a mechanical problem in the hubs. Plus you have to have a good battery and charging system for awd to work properly. Whether chain driven like yours or shaft driven,awd system is the same.Here's a video from a Sportsman 500 that shows the jumper wire mod.

 

my wires from switch run into a fuse panel and then disapear and not sure were they run after that do i need to do it before fuse box or after

 

This is just the terminal board. If the awd lights up on the throttle assy,the gear shift position switch in the gear box is working ok. Check that you have power to the small grey wires leading to each strut in the under the front panel. If you have voltage,then it's still possible a grounding issue. The only fuse is a 20 amp circuit breaker in a sealed pouch up from the battery. If it was shorted out you wouldn't have power to ign switch ,lights,awd etc. Here's a pdf manual that can help you on problems.http://gh-ftp.com/ORV%20Manuals/Pola...e%20Manual.pdf