Your model has the terminal board in the center. All you do is trace the gray shift switch wire to the board. Unplug it and insert it in the red/white terminal section.This should allow the awd button to work. On the throttle cable you can check it under the panel also for any binding.If you ever run into me just buy me an iced tea.. Terminal board is item #39.

 

I got one culprit out of the way - the throttle was sticking because of some ugly aftermarket grips that were making it bind. I jerked them out of the way in a hurry.

The gray wire thing is giving me a fit, though. I am trying to follow any wiring from the shifter but I see and feel no wires whatsoever. Under the hood I see bigger gray wires that lead to the 2 terminals that I grounded the brown wires the other night. Those 2 blocks have a bigger gray wire coming into each one and a jumper gray wire to each other.

And I'm sorry - is the terminal block on the left here in the photo? I see a white and red striped wire on the right but just a solid red on the left.

 

Better shot of the wire cluster on the right side.

 

Look to the upper left of the items in your pics that show the wiring from the stator to the cdi and coil. If you have the 2000 model should be a terminal board I showed on the thumbnail pic.There you can find the wires that run from the board to the gear shifter switch.

 

It just got out of the 20s at night so I can work with it now - I'll get a picture to you soon. I was going to try to change the brake pads - and rounded off one of the wheel lugs. Are there some better replacement lugs with higher walls besides these little ones that are hard to grip?

 

Never had any problems with these 9/16"(14mm) lug nuts. Use PB blaster or liquid wrench.

 

I ended up having to chisel the lug nut off because the lug thread apparently was damaged. Got the brake pads all replaced and got rid of the squeal in the front end! I also replaced all the small lug nuts with bigger ones that are very easy to get off.

I hope to get under the hood this weekend to check on this 4wd problem - I'll try to get a picture up here.

 

Hey Guys,
I have the mechanical speedometer and the cable is broken.(1999 Polaris Sportsman 335) Do I need the Speedo in order for the AWD to work? I can't get the awd to work. I replaced one of the wheel coils as it wasn't magnetizing - now both are receiving signal and magnetizing but still no awd.
Also for some reason, I cannot get the right adjustment on the shifting linkage. On a slight turn I can get the High gear to engage but the reverse will not. Turn the linkage the other way slightly and I gain reverse but loose High gear. Could there be another issue? The awd light doesn't come on either. What else should I look for?