I am having problems with my AWD. I have AWD in reverse but nothing in either forward gear. THE AWD works with both the override button engaged or not engage in reverse. I changed the oil in the front gear case and it was good. I haven't taken apart the hubs yet but I am wondering why it would work in reverse but not in low or high forward gears.

 

is this an 04 or 04.5 year. you said hubs so im guessing it must be 2004 and not the 1/2 year w/ the new style hillard. if so make sure the hub fluid is goos and you have power down to it(sounds like you do) and that the transmission switch is working so the bike knows what gear its in as it all works together and if the speedo doesnt work then neither willl the awd. imo.

 

It is actually the 2004.5 model that I have.

 

)4.5 what? 5, 6, or 700 what?

 

My front differential will not disengage. I have a 2005 800. I unplugged the wire from the switch and it is still in 4x4. I changed the seals and bearings last weekend but nothing changed with the awd

 

i hate to say it lift master, but it sounds like you have the dredded broken roller cage in the front end.

 

We just changed all the bearings and seals last Saturday.. Everything looked fine. It was extremely clean inside.

 

Sorry, I should have included more info. My atv is a 2004.5 Sportsman 500HO. As I stated before, the AWD only works in reverse. To me, that tells me that the AWD works and engages but for some reason, it doesn't engage in the forward gears. The speedo works fine. I checked the transmission switch and it seems to be working ok also. On the speedo you can see the gears and the 4X4 switch engaged. I also checked and proved that I have power going to the coil. What else tells the AWD to engage. I understand that it only engages when there is 20% rear wheel slippage but what tells the AWD that there is this slippage?

 

We took the front differential apart and found the armature plate had two tabs bent keeping the roller cage from sliding into position. Now it is out of awd but will not engage into awd. There is power to the connection. I did notice a nicked place in the coil about an inch long with copper wires showing. How can I tell if this is causing a short.

 

do you have any buddies with the same four wheeler, maybe you could borrow there speedo and see if that changes anything, thats what it sounds like to me, this way you can try it before u spend the cash on a speedo