I think if it were the reverse override switch that was stuck, it would also light the [R] "reverse" indicator on the dash. But worth checking none the less.

When you are in forward with the awd switch in off position, when you push the reverse override button, does it light your [R] light on your dash? If so this points to that side working.

I think the two switches work collectively, meaning when you close one circuit on the awd switch, you need you close the other circuit for the reverse bypass, to spin your front wheels. This may explain why disconnecting the bypass switch changes the behavior. I still feel problem is on the awd switch side.



nth

 

Low battery can screw everything up, yeah put the bat on and test things again.


nth

 

<div class="FTQUOTE"><begin quote>Originally posted by: nth500
When you are in forward with the awd switch in off position, when you push the reverse override button, does it light your [R] light on your dash? If so this points to that side working. </end quote></div>
Yes it does.

I'm going to let this new battery get a good charge and see what happens. I'll keep you all up to date!

 

I put the new battery in tonight and it still does the same thing [img]i/expressions/face-icon-small-sad.gif[/img] It won't go into 4WD and I didn't ride it long enough to see what happened once it warmed up. I'll clean the switches and plugs again when I get a chance and see what happens.

On a side note: when charging the new battery a little acid leaked out of the hole on the side (maybe a weephole or something). It was just a little. After riding I checked it again and there was a little bit of acid that had leaked out again. The dealer filled the battery with acid. Is this normal or should I be worried? Should I keep that long tube on the hole?

 

Forgot to mention that I did charge the battery with the 2 AMP mode.

 

You should put the long tube on .....This hole and tube are for the gasses to be released when the battery is charging......even when in use on the quad!!......Caper......

The tube will help keep the hole from getting plugged up with mud or dirt!!

 

I'm still working on this. I've found that after about 5 minutes of riding (with a lot of switching between forward and reverse) it will become stuck in 2WD to stuck in 4WD all the time. I've notcied that it goes into 4WD when I'm backing up and the right hub will lock sometimes right before this happens. What about the magnests in the hub? Could these be the problem?

 

I heard you need to use the proper Hub fluid for this type of problem(Polaris oil only!!!).....I really don't know if this applies to your year and model?...........Caper..........

 

That's what I've heard too. I have ATF Type F in there now. I might have to break down and make the long drive to the dealer to get the real stuff. I might try changing the hub fluid one last time before I do that. I noticed yesterday that the left hub locked on me while backing up.

 

Who told you to use ATF(automatic Trans Fluid) Type F?????..............Caper..........