Ok,now jump the brown/white wire from the speedo harness connector to the same grounding point you made for the diff ground. See if the front wheels engage an the awd light comes on. If not go through the speedo harness connector pin test in the manual.Problem could be there.

 

I jumped the brown/white wire to the frame with the other wire. The Speedo is still not displaying anything at all. I started the 16 pin test and number one has 12.27 volts and number 2 has 11.66 volts. The battery has 12.30 volts. Book says they should be the same.

 

I plugged the Speedo back in and now it works. Not showing the gear I am in so going to do that test. Ugh

 

I checked the resistance on the resistor it was a little off but I took it off and cleaned the resistor chip. Plugged it in and now ever gear shows on the Speedo. Still no awd. It is not lighting up on the Speedo and I can free spin the shaft coming out of the front dif. I still have voltage on the wire going to the front dif.

 

The resistance on the awd coil is 23.3 right where it should be according to my book. I have 12 volts coming to the plug. I can't do a back prob for some reason. Very confused...

 

Connections may have been a problem or the speedo itself,but it's been bypassed as far as the awd is concerned. If you have power to the dif grey wire and have made a better ground,problem could be in the diff coil itself or a mechanical problem with the roller cage.If coil is ok,it should show between 22.8-25.2 ohms between the gray and brown/white according to the manual.If it's within range, might be that another cracked plastic roller cage is the problem.

 

It ohmed out fine. How bad is it to change a roller cage?

 

Hard part is getting one out. Here's a video on a Rzr.

 

I got the front dif out and took it apart and nothing is broken. I can send pictures if need be... I don't understand it ohms out fine. I have power to it. Has to be the Speedo? The Speedo is 8 months old!

 

Change out the plastic roller cage and armature plate no matter what since you're already in there. The cage can have small cracks hardly visible that can cause engagement problems.I'd also check out the coil plate with 12 volts also to make sure it's pulling the armature plate. Again if you've jumped the speedo connector brown/white wire to another brown or a better ground,you've eliminated the speedo from interfering with awd engagement.