Hi opt, awd just stopped working... I don't know why? Also u joints are shot in the shaft that goes from the trany to the front dif. Is it hard to get the shaft out?
07 500 sportsman efi

thank you sir

 

Use an air hammer with a ground down bit to remove the roll pin at the front diff prop shaft yoke.Then it's easier to just change the bit to a dull flat one and impact the rear prop shaft yoke toward the gear case until the yoke comes off the front diff. Angle it to the left of the diff,then impact the rear yoke off the gear case shaft. Then you can slide the prop shaft assy out from the front. You can get the u-joints ,but if the yokes are damaged in anyway,may be best to replace it as an assy. Polaris ATV Parts 2007 A07MH50AB-AL-AQ-AX-AY-AZ-MN50AF-AN-AT-AY SPORTSMAN 500 EFI SHAFT, PROP Diagram

 

Okay will do thank you. The shaft and u joints are still intact but when I flip the switch to awd nothing lights up on the dash. That's what made me start investigating and that's when I found the u joints were bad. What could cause the awd not to light up on the speedometer?

 

Front diff power wire is Gray with a Brown/White ground wire.May be the old ground problem that many have had. The awd ground wire goes from the switch through the speedo and then to the front diff. On the speedo connector wiring jump the Brown/White(awd ground) to the common Brown ground wire in the harness. This bypasses the speedo entirely and hopefully will allow power to the diff and the awd light should work.

 

If this fixes it, it will still show the 4 wheel drive picture on the speedo?

 

Does this look correct? I have continuity between tgese two wires regardless of where the switch is

 

I used a blue splice connector to jump the brown to the brown white and now it doesn't show what gear I am in in any position...

 

 

Make sure you have power to the gray power wire on the diff to start out with.Take the scotch locks off the two wires and jumper the diff ground wire directly to a better frame ground or brown wire to test. If the awd light still doesn't come on,problem could be in the awd switch itself in the throttle control. Get the cheap manual on this and go through the trouble shooting guides and checks on the awd system.This can help you narrow down the problem area.2007 Polaris Sportsman 500 EFI Service Manual PDF Download

 

I have 12 volts on the grey wire down by the dif but I did not have continuity from the brown wire to the frame on either side of the connector. I spliced into the brown wire and used a self taping screw and connected the wire to the frame. Now I have ground on the brown wire. But now the Speedo doesn't light up and doesnt display anything but it has done that before in the past... I have a clymer manual. Do you know if that covers any of this. I am getting confused now... I have the prop shaft out of right now and the dif free spins.