Try flicking your kill switch back and fourth. That usally works for me.

 

I checked everything over. I looked the wires over and everything looks good. The light looks good on the switch. It still is not engaging for sure. I could spin just the rear tires when it should be in 4WD. I didn't try the kill switch, but I'll try that next. My left wheel does seem to be a little looser than the right side. I couldn't find the washer that you talk about 94harley. My genius buddy said to pull the cover off the hub and check to make sure everything is good. He failed to tell me that it is full of oil. How in the world do you put oil back in this thing?

 

<div class="FTQUOTE"><begin quote>Originally posted by: cdrmotorsports

I checked everything over. I looked the wires over and everything looks good. The light looks good on the switch. It still is not engaging for sure. I could spin just the rear tires when it should be in 4WD. I didn't try the kill switch, but I'll try that next. My left wheel does seem to be a little looser than the right side. I couldn't find the washer that you talk about 94harley. My genius buddy said to pull the cover off the hub and check to make sure everything is good. He failed to tell me that it is full of oil. How in the world do you put oil back in this thing?</end quote></div>

Before you worry about the oil worry about getting it back together correctly. If you do this job wrong it can ruin a bunch of expensive parts. I will send you a pm to call me. There's too much to explain here. How far did you tear the hub apart?

 

All i did was take out the hex screws and start to pry the plastic outside cap off and then oil started to poor out, so I put the cap back on and then put the screws back in. I didn't touch anything inside the hub.

 

Ok good. You didn't hurt anything. If you remove the cap you will see a nut with a cotter pin in it. the washer I was referring to is behind that nut. Raise the front end and put one hand on the top of the tire and one on the bottom. See if there is play in the bearings. If there is you may need to tighten them back up, but it may be caused by that washer being bent or worn. If you remove the nut, don't let the cv joint move inward, if you get play in the hub/beaerings, hilliard clutch, etc. and try to reassemble it, the armature plate can get dislocated. If that happens and you tighten it up, bad things will happen. Fill it with oil through the allen head plug on the side of the hub.

 

<div class="FTQUOTE"><begin quote>Originally posted by: 94harleyFill it with oil through the allen head plug on the side of the hub.</end quote></div>

How do I do that? What oil do I use? How do I know when it's full? Thanks again for all your help.

 

<div class="FTQUOTE"><begin quote>Originally posted by: cdrmotorsports

<div class="FTQUOTE"><begin quote>Originally posted by: 94harleyFill it with oil through the allen head plug on the side of the hub.</end quote></div>



How do I do that? What oil do I use? How do I know when it's full? Thanks again for all your help.</end quote></div>

Well, remove the plug of course, fill it with Polaris demand drive hub oil. Or you can use something like ATF. Fill it until it runs out of the hole at 3 or 9 oclock position. Put the plug back in and your done.
Did your wheel bearings have any play? Also, does the awd light illuminate when you turn on the AWD?

 

I havn't checked the bearings yet. I've been really busy and probably won't get to it until Saturday. I'll put some ATF in that hub because I have a few quarts left that I bought last weekend. The light does not light up when I put it in AWD. Thanks again!

 

<div class="FTQUOTE"><begin quote>Originally posted by: cdrmotorsports

I havn't checked the bearings yet. I've been really busy and probably won't get to it until Saturday. I'll put some ATF in that hub because I have a few quarts left that I bought last weekend. The light does not light up when I put it in AWD. Thanks again!</end quote></div>

Check into the electrical part of the 4wd not working before you go to the mechanical side. Make sure the light is good(I forgot to check the schematic at work, sorry) so I don't know for sure if it HAS to illuminate before the 4wd works or not. Did you put the machine in forward, awd switch on, key on, and manually push on the gearshifter(further forward&lt; like you are trying to push it past forward) and see if the light comes on? Try that if not and let us know. I have a hunch it's an electrical problem rather than a mechanical one.

 

So here's an update: I refilled the hub oul (thanks 94harley!). I jacked up the front end and checked the bearing. All seem to be good. I flicked the kill switch a few times and still nothing. I turned the switch and key on and pushed the lever as far forward as possible and still nothing. I then took the top off the housing where I thought the light was (above the throttle button), but there is no light in there. All I see is some clear glue around where I think the light should be. Am I looking in the right place? I then spun the front tires around while it was jacked up and noticed that on the right side only it makes a clicking sound. It has no pattern or rythem to it. It only makes it when I spin the tire somewhat fast and in the forward direction. If I spin it the towards the rear it doesn't make the sound. What's going on?