Check and see if there is a three way toggle switch in the shifter block, just look at it and see if there is a conduit with wires inside it, the switches go bad and can cause that problem.

 

My 96 Xplorer had the same problem. I cleaned the push button and the problem cleared up for a little while. I later discovered that it was the microswitch that runs from the shifter to the curcuit board. I let the guys at the shop handle that job.

 

On older machines, the shifters get a little sloppy, mud gets everywhere, and things start to show their age.
One of the most reliable ways to solve all this is to bypass the entire shifter switch, override switch and reverse rev limiter.
This procedure has minimal side effects, (Full power reverse WITHOUT pushing the override, and in neutral, the reverse light will be on)
My g/f Scrambler 500 has been a great machine, but about a year ago it started having intermittent AWD failures. After having it fail once on a STEEP hill climb, and once in a long mudhole... I BYPASSED IT ALL.
If you allow kids or inexperienced riders on your bike, you might not want to do this. (because of the full power in reverse... You can run literally as fast in reverse as you can in forward.) Variations to this are to bypass everything EXCEPT put the rev limiter (sputter box) on a toggle switch. That way when the less experienced riders are in control, you can enable the box. If you will do a searchh on Reverse Override bypass, you will find DETAILED instructions for making this modification....
Good Luck...

 

Deej,
If the other people on this forum do not beleve you, have them get in touch with me. I have an unlimited supply of front hub sensors for $399.00 a pair. I pay shipping.

If you do have an older bike and don't want to pay for the new parts, I would just do as mudmachine explained.

Greg

 

Gregsims,

If I am referring people to you for those AWD sensors then I expect at least 50%! LOL

DJ

 

The bike should have Gear Oil in the front hubs. I know it may be simplistic, but it is worth a check anyway.

 

But when you have more or less air in the back tires they spin at a different speed. So somehow you dont really have ot wait.

 

Since I have bought the fourwheeler used (four months old) the AWD light has never worked. But the AWD did. Also I have had several other electrical problems. No tailights,(but brakelights) And headlights really dim. I fixed the headlights by cleaning the connections and they work, but I haven't got around to the taillights.