Alright guys, I think I might be getting a hold on this. I drained the hubs and refilled them again today. I drained and refilled the front gearcase mulitple times. Still having the same problem of the AWD not wanting to engage or disengage. I played a round a little and found that if the AWD is stuck on and I back up without pressing the override switch it goes straight to 2WD (as it should). That got me thinking. I unplugged the connection for the override switch and I had 2WD forward and reverse. Plug it back in and it is stills tuck in AWD whether the AWD switch is on or not. I cleaned the heck out of the connection and it still has the same problem. I guess this rules out any mechanical problems? What is the link that I'm missing to fix this problem?

 

I forgot to mention that the AWD light is on whenever all four wheels are engaged, even if the switch is off (I can see the light on through the housing). The only time it turns off is when I back up and don't hit the override button (but I'm in 2WD anyway). If I'm in 2WD the light is off. If I'm in 4WD the light is on. It turns off when I'm in neutral. So that part of the equation seems to be working correctly.

 

If I was to guess, I would say the 4wd switch is defective. Or you have a wiring issue and the wires coming to and from the switch are shorting out somewhere.

 

That's what I'm thinking, but I've looked and tried out everything. Still can't find anything that might be the problem. Can I replace just the button of the switch or do I have to replace the whole assembly? What does diconnecting the override switch do to kill the AWD instantly. Are there any fuses or anything to check? I want to look at every possible thing before I start buying parts without a clue if they are going to help or not.

 

Do you know anyone cool with a scrambler? Maybe he'd let you try his switch and see if it fixes your problem. Do you know the cost of this switch? Deduction does lead to the switch being the problem. (I'd check wires really good before you buy new switch). As I have bought new parts in the past to find it was not the problem. If the switch is reasonability priced, I say buy it. 75%/25% it fixes the problem. Seeing how it is incorporated into the thumb go fast button, it could be spendy. but no offence your bike is a few days old (mine too bro). A few new electronic parts never hurts a machine you intend on keeping for a while. Just my three cents.

My AWD light is not on under the switch when in 2wd.

Have you removed the entire switch assembly and cleaned the contacts inside the housing? I don't mean just the connector that plugs into it. I am referring to the guts within the assembly. The actual switch itself. Looks somewhat sealed, but if you are looking to buy another one anyways, crack her open and take a look, and do some contact cleaning.

If the switch is really bad, cleaning it may not fix the problem. Maybe you can trace the wire that this switch connects/breaks and bypass it by cutting it. sounds extream, but will answer your question one way or another.

Nth

 

Thanks nth. I don't know anyone around that has a Scrambler. I'm going to take the switcah apart and give it another really good cleaning along with all the other connections and see what I can come up with. It doesn't hurt to try it again. Partsland.com has the whole assembly for $142. Yikes!!!

 

E-BAY!!!!

 

If the override switch seems to affect this awd problem, are you going to clean it as well?? I know my override switch stuck in once and my wheeler tried to stay in awd even though the awd switch was off...weird but true!!

 

If I recall right, when you are in drive, 2wd, and push the rev. override button, it will light up the 4wd light. Maybe the problem is in the override switch. I would test both switches with an ohm meter and see if one is stuck on

 

I've cleaned both switches really well. I can't find my OHM meter (or my buddy never returned it), so I'll have to track it down. I notcied something else today. When I put it away yesterday it was stuck in 4WD. After letting it sit overnight I ran it this morning and without touching a thing it was in 2WD and would not go into 4WD. I ran it around my property for about 15 minutes and flipped the 4WD switch. It engaged as it should, but would not engage. I was wondering if it had something to do with the battery being low. I took the battery out and found it was leaking a little from the negative post. I went and bought a new battery. It's being charged right now, so I'll have to see if this cures anything. You never know!!! it could be something really easy like that.