Need some help. When I select AWD it activates the AWD display on the pod but no front engagement. I have draing and refilled the front diff. Flushed and refilled diff again( looked cloudy but no metal or chunks). Traced the wire from the diff back to the pod and looks good. I dont see any fuse for it (the 4 fuses by the radiator are good). There is a quick disconnect near the pod and when that is disconnected the AWD display goes off on the pod( I assume that shows juice is getting to the diff). Other that pulling the diff apart for a look see I have no idea what to do to help trace my problem. The AWD was working one weekend then the next time I went riding it just was not working. I will sent cookies to who ever guides me to the solution to my problem.

Thanks for any help
MH

 

WHAT KINDA COOKIES,,, BUD LITE WORKS TOO... LOL.... DOES NOT WORK AT ALL, FORWARD OR REVERSE

 

Make sure that you use the Polaris On Demand fluid and not just regular gear oil. If you did and it's still not working, what I had to do is open it up and clean it up inside.

 

Get a service manual and check the troubleshooting section. My AWD stoped working in forward but worked in reverse because the plastic cage that holds the rollers was destroyed. I have seen the same thing happen to my friends except the AWD didn't work in reverse but did in forward because the plastic cage was broken.

 

Does the awd light stay on in forward and reverse? Or do you get no engagement into forward? If the light stays on in forward and the front tires do not turn and you changed the oil, by the way how full did you fill the hub? Should be filled to 2 or 10 o'clock. If it still does not work check for a broken wire to the coils. Or you might have to take the hub aprt and check the armature plates to see if the ears are worn off(not to bad of a job).Hope this helps.

 

The sportsman 700s use a diff and not the two hubs to engage the AWD. It works on the same principle, but on a larger scale in the diff. Should use the same fluid as the hubs did on the older sp 500s. You can check to see if the switch is sending power to the diff to engage the "magnet" which engages the rollers which inturn locks the diff and gives you "posi trac" in the front axles.

 

First off-- thanks everyone for shareing your knowledge.
-The AWD lite seems to work properly (on in fwd and on with overide button in reverse)
-I filled the diff with factory fluid until a little ran out of the fill hole- looked like the factory recommended 5 oz.
-How do I check to see if the "magnet" is activated? I believe power is reaching the diff( When I unhook the quick connect in the wires leading to the diff the AWD lite turnes off) but something is preventing it from activating
-Unless someone has a better idea, I think I need to remve the diff and open it up. What is the best way to remove it? Do I remove the radiator, or will it slide out sideways once I remove the hubs and axles?

Thanks for any further help,
MH

 

I have taken my fron diff out and rebuilt it on my 700. It was 3 or 4 years ago so I'll give the directions a try. If you remove the front tires and front drive shafts out of the diff then you can remove the elec. fan and pull the diff out. The plastic cage is spendy, about $230.00, but if you do it yourself you can save about $500.00.

Like I said before troubleshooting is easier then just ripping stuff apart so get a polaris manual first. Also check to see if the AWD works in reverse.