Ok, first thing...Hello. I'm new to this forum.
Now, 2004 Polaris Sportsman 500 ATP, has 4x4 issue. It came to my shop not engaging at all. I have been able to get it to engage, but only sometimes. When I put it on jacks, all wheels off the ground, put the shifter in H, move switch to AWD, give it gas and when the rear tires get to @ 20mph(I'm guessing b/c the speedo is dead) the front will engage. Put shifter in L and the same happens when the rear wheels reach a certain speed. Same for reverse. The override doesn't seem to be working. It runs wide-open in reverse w/o hitting the button.
Now, the trick...when I take it out for a ride, get in some mud so the back wheels spin, IT WILL NOT ENGAGE INTO 4X4????
Any help????
And, what are the 2 wires that go into the front differential/
As you can tell, I'm not a Polaris expert.....THANX!!!

 

Replace the speedometer. AWD will not engage if the speedometer doesn't work.

 

Then why does it engage sitting on jack stands, and not while actually riding? That is the confusing part....thnx

 

I have heard on the '03 and newer models, there is some part in the front gearcase that often wears out. After this happens if the rear wheels are spinning fast enough while the front wheels are stationary, the front will engage. The two wires you see going into the front gearcase magnetize some plate to activate the AWD.

 

Ok, here is what I did.....Since 4x4 would sometimes work i figured the speedo being dead was a big part of the problem. So, I unplugged the 2 wires that go into the front differential. I ran one wire to + on the bat. and the other wire I ran through a toggle switch and then to the -- on the bat. Without the toggle switch 4x4 stayed on ALWAYS. So, I put the switch in the circuit and wala.... 4x4 comes on & goes off by the toggle switch. Now when you turn on 4x4, the front wheels engage even if the back tires don't spin. I guess I'll find out if it lasts....goin muddin now to test......Thanx..........