I am trying to figure out why I have AWD in reverse but not in any forward gear. A week ago I had it in forward but not in reverse all the time. The AWD is also engaged while in reverse regardless of weather or not I depress the override button. Any Ideas?

 

sounds like the override button is shorted out

 

Yes I agree you have a short or an occasional short. Now you have two buttons. One to switch the AWD on and off and the other red button on the left is the override for reverse. To operate the AWD in reverse the red button must be pressed. Well with my atv the red button I can also change modes on my speedomoter. If you can change modes without a hic up then the short is probably in your AWD on/off swtich. Good luck, thats all I know.

jeff

 

do you have a digital speedo? one that shows you what gear you are in? im thinking that the sensor that tells it what gear the tranny is in (all models have this) is loose and reading incorrectly
the reason i ask about the speedo is its the easiest way to tell if the machine can tell the correct gear or not

 

The override button short sounds like a good bet. I'll test the switch. An occasional short sounds possible as the problems seem to change. The bike was engaging the AWD w/o depressing the override button yesterday but now I have AWD in reverse when I depress the override button only. Yet still no AWD in L or H. The bike is a 2002 sportsman 700 with a digital speedo and I can go through the diagnostic mode w/o any problem. Also, the AWD button appears to be working properly and the light is functioning. The digital speedo indicates the correct gear that the machine is in but I'm not sure if is sending the correct signal to the AWD. When I test the voltage at the plug that goes to the AWD hub, there are two sets of wires. The one side is two grey wires that reduce to one and then go to the hub. On these wires I have 12V all the time. On the brown and white wires I have 12V in P N and R. But when I put it in L H or reverse with the override button depressed it drops to 5 or so. I have checked the resistance in the hub and its right where the manual says it should be( about 25 ohms) I'm not a mechanic but I'd like to try to figure this out. Are both sides (Grey and brown wires) of the wiring harness that goes to the hub supposed to read 12V all the time when the AWD switch is on?

 

You have a broken roller cage in the front diff. My 02 700 was doing exactly what yours was, i put in the john deere roller cage and armature plate, and it works perfect now. Cost was 70 bucks, part number mia10667...

 

Thanks for the advice,
I did some more tests today and found the following while the quad was up on blocks and all wheels were off the ground. The AWD switch light comes on as it should. The AWD works in reverse when the override button is pushed and continues to work after it is released. The AWD also works sometimes after shifting into high or low, spinning the tires and then returning to reverse. I am still not sure what the voltage should be at the wires that go to the AWD hub. There is one grey wire that has 12V all the time and one Brown and white wire that has 12V except when in H L or R with the override button pressed, it then drops to .3V It seems like the roller cage is engaging in reverse and then getting kind of stuck. I guess I need to take the hub apart and see what's inside. I also changed the fluid in the front gear hub and there were a few tiny flecks of metal in it. I don't know if this is normal wear and tear or not. Is replacing the roller cage a major ordeal?

 

what year is ur machine

 

The machine is a 2002 sportsman 700