My wifes 4x4 is not working. I jacked up all four tires to see if the would spin, but they dont. This Machine doesnt have the 4x4 button and light like my 97 does. It has a yellow switch that says on and off, and no light to indicate if its working. Which is strange, because her owners manual shows a button and light. Anyway, where should I start looking? I added hub fluid, which it wasnt low.
Buk

 

Hello try holding ahead on the gear shifter in fowards (hi or low) when you try it as for the yellow switch when 4x4 is on the letters awd uncovered by the switch shoud light up thear should be a light bulb in the throtte block behind the switch

 

I tried holding the shifter hard in all gears, including reverse. No 4X4. The axles are spinning. But not the tires. The AWD light does not light up. I suppose check the bulb first?
Buk

 

Try checking your hub fliud levels.

 

My hub levels are fine. But shouldn't the 4x4 light be on anyways, regardless of fluid. It is my understanding that the light is at the beginning of this system. Is this not the case? I also looked at the bulb last night, but cant tell if its blown. How can I test it? If its bad, How do I change it out?
Buk

 

You are correct, the AWD bulb is wired in parallel to the right hub coil, and the right coil is wired in parallel to the left. You should check the wiring on going to the coils, and clean the switch contacts as well. If you have access to a multimeter you can test the bulb to see if it is bad.

 

Now I'm not an electrician, but I do have a multimeter for some reason. The bulb is showing the 9 volts on the meter going thru it. I cleaned the contacts. All wires from the hubs appear intact. What next? Since I have a book for a 97 I didnt see the need getting one for the 99, but apparently its different enough that I need too. There are 6 wires coming out of the 4x4 switch, From top to bottom, Black, brown, brown w white, grey, grey, grey w white. The brown is getting twelve volts. Nothing else is, switch on or off. Should the AWD light be on when ever turned on, or only when it ingages on its own? Just curious if I need to keep jacking it up every time I get a brainstorm to check something else. Starting to wish I would have bought new ones.
Sorry for being a pain in the arss.
Buk

 

You can download both the manuals from the Polaris site, if you cannot get to them, let me know and I will email them to you. There is a detailed wiring diagram in the owners manual.

 

Ok, got the diagram. Tell me if Im wrong here. Black ground, brn power from ign, brn w white to r coil, grey to r coil, grey to left coil, grey with white to override. This being the case, If I have 12 volts at the Brn wire, and assuming my bulb is good, It almost has to be the AWD switch. Is this correct, or am I seeing the power coming from the wrong direction?
Buk

 

That sounds right to me, to test the AWD switch, just run a wire jumper across it. If the light comes on and the front tires start to work, then you need to replace the switch.

It could also be your reverse overide switch, you can bypass that since it is really useless anyway. I have seen this happen before.