I have a 2004 Polaris 330 Magnum. Recently the speedo unit went kaput, and the machine would not engage 4wd at all- even with the AWD switched to ON. Tired of digging the machine out of mud, I wheeled her into the shop and traced the wires to the front diff/AWD. The speedo unit stayed plugged in and tucked under the front "hood" and I wired a rocker switchroof switch to engage the front diff- the switch has "key on" hot, a good ground, and loads one of the diff wires, the other being grounded. This worked like a charm for a few hard riding sessions and especially with the new ITPs I am running. But stuck in a miserable hole (oh for a few inches of clearance more) the switch was thrown while the rear wheels were turning (not fast, but maybe at quarter-throttle or a bit more) and with a clunk, they engaged for the last time.

Now I know this sounds like roller cage issues, and I'm sure it is chewed up pretty bad (and if anyone knows the JDeere part number, that would be great!) and needs replacing. But, with this switch, sometimes the front diff would lock, sometimes it wouldn't. And to get out of AWD I always had to turn the switch off and back up. PITA.

So, aside from the apparent plastic chaos inside the diff, is the switch going to work? I mean, forever? If key on is 12volts, is that too much for the front diff locker? I don't want to spend money on another speedo unit, nor buy a new diff (unless I can retro fit a later diff into this machine that is beefier and has limited slip).

Any ideas?