So i am working on a 1999 sportsman 500 for a friend and when the awd light is on the 4 wd works fine. But when i turn the switch on there seems to be a delay before the light turns on and sometimes it does not turn on at all. I checked the conections and lubed them. wiggled every connection that pertains to it. even checked the connections at the transmission. Could it be a bad switch at tha trans? The same thing happens when i turn the ignition switch to off and then on the awd light sometimes comes back on with a delay and sometimes not at all. But again when the awd light is on everything works fine. Thanks!

 

I believe that you have to "roll" the machine a little to allow the gears to mesh

 

I did move the machine back and forth. Doesent make any difference.

 

Nobody has any ideas what this could be?

 

Could be the switch. I took mine apart (02 Sporteman 500HO) and found it was full of dust. I cleaned it up, put dialetic grease on , and it has worked fine since.

 

mine had the same problem but it had water i the wiring so i clened it