Just blowing off a little steam but I'm trying to get the AWD to work on my 03 Sportsman 600 with 400 babied miles. The AWD never gave me a problem than just quit, no light on the AWD switch. I replaced the gear switch on the tranny and checked all of the connections and wires. I thought the gear switch would do it but no dice.

I need AWD to get through the trails around here and the quads been sitting. I did a search on the major quad sites and came up with the tranny switch going bad is the most common AWD failure. I bought a fancy voltmeter and I'm looking for advice on the step to take in getting the AWD to work. The correct fluid is in the front differential.

Please help, I'm starting to lose confidence in this machine.

 

Did you check the voltage regulator?
It's in front of the radiator.
Mine(AWD) went out twice and both times I had a broken wire.

 

I had a broken wire to one of my hubs one time. Fixed the wire and problem gone. It sounds like you are having alot of problems with your 600.

 

I know a few things that will make the awd not work. The speedo, the hall effect sensor, main switch, shift indicator switch, voltage regulator, broken wire going to hub. Any of these malfunctioning will stop the awd from working.

 

Thanks guys, I'll check it out in the morning. All problems so far could be fixed using the shop manual or searching the forums. My Sportsman is in mint condition and I maintain it to the hilt. When I bought the tranny switch today, if my dealer had the 800 Bombs in we would have sat down and talked.

Any more AWD solutions would be great, Thanks

 

O.K., I've calmed down a bit, I'm going to fix my Sportsman 600 and enjoy it.

 

Thank God. 3wd honda? Get some help

 

One little problem and your bad mouthing and ready to jump ship.

A real loyal kinda guy.

 

Best thing I ever did to my quad was bypass all the sensor BS. Now when you hit the awd button it's in AWD. You put it in reverse and you have power and awd all the time.

I bypassed the shifter switch and the reverse switch's. Makes for a much nicer machine.

 

Easy now guys, sometimes you have to get creative for someone to reply to your post. The good news is it's fixed, it was the AWD switch on the handlebar. The contacts where alittle tarnished and l cleaned them up with some sandpaper. However it was the last thing I checked, I chased each wire and cleaned-up and lubed each connection up and down the quad.

I thought the AWD switch was incorporated into the throttle and EMC so I was leery of messin with it. I broke my own golden rule to first check what ever is cheap, easy and free.

The Sportsman has never left me dead on the trail but this was by far not the first little problem.

Thank you all.