Well here is the deal i have a 2004.5 sp 500 ho and the machine has 20 hrs and 130miles now the problem is is that it stays in four wheel drive all the time but it is kind of catchy or grabby in and out quickly but not as much when you put it in AWD...i checked this by having the front and rear end suspended in the air..now i checked the hub oil and it is good and full...i checked the diagnostic and when you put it in AWD it says ON and when you put the switch to off it says OFF in the diagnostic....I think it has been doing this since it was new but i havent thought much of it...and im not bringing it to the dealer even if it is under warrenty cus they will screw it up more than it already is so any ideas, i hope so....thanks oh yeah and you cant freely turn the front tires in reverse even when the awd switch is on off...

 

The coil for the AWD in the gear box may be grounded so its on all the time. That system is controlled by switching the ground rather than the positive side of the circuit. If the problem is in the gearbox than it will be a spendy problem. You dont have to go to the place where you bought it for warranty work.

 

do you mean the transmission or the front gear case now how do i check that this is the problem????thanks by the way i was waiting for someone....

 

You may not care for my advice if you dont like dealer service. With the low miles you have on your machine the its likley you have a defective part or an assembly problem. To many possibilities to discuss online. Find a dealer that is reputable and bite the bullet.
That would be the front gearcase with the centralized hilliard clutch. If you are not familiar with that then I suggest you buy a service manual.