Well my battery went dead on me the other day on my 02 Sportsman 400 so when I replaced it my speedometer wasn't working. Everything lights up the needle just doesn't move. I believe this could be the speed sensor. I read that there is a quick fix here http://forums.atvconnection.co...AR_FORUMVIEWTMP=Linear
So where do I cut the wire and where is the best place to ground it?
Before I read that, I tore down both hubs using this guide. http://www.atvtime.com/phpBB2/...7aa0f67fc0c7a30cead999
I cleaned everything, all measurements came out right, and tested magnet and both worked properly. On one side the hilliard clutch(I think thats what its called) one of the rollers would stick. It wasn't horrible, it just didn't move as easy as the others. On the other side though all were perfect. The only other thing I did notice is that the spring around it did seem like it may have been a little loose. How tight is it suppose to be?
Anyway, I replaced both armature plates, put everything back together, torqued to correct specs, filled hub fluid, and still no 4x4. Do you think that the speedometer is definitely the cause? Or could it be that spring or roller in the hilliard clutch? The 4x4 always worked perfect and not its not working at all!
Please I would appreciate any help, I really don't know what else to do!

 

There is a linnk fromm the speedo to the 4x4 system. I think the speedo must work for the 4x4 to receive the electrical signal to enage. Ask Old Polaris Tech in a PM.

 

my speed sensor was not working but my 4x4 still worked

 

not 100% sure on this, but if your getting power thru the awd switch i think it would be working as im not too sure if the 02' speedo controls the awd or not. i also think you can bypass the sppedo for the awd w/ the brown wire on the speedo plug in by grounding it out(again not 100%sure) so maybe someone w/ more knowledge will chime in.

 

I don't think that it is the speed sensor because when I turn the key on the magnets are working. I really don't understand what it could be. Could the garter spring on the cage/rollers being too loose cause it? How tight is it suppose to be?

 

yes the spring being to loose could cause it not to work right