Does the speedometer work properly? It needs to work for the AWD to work on 2000s modles and up.

Does it have the older twin Hilliary locking hubs or the newer single Hilliary locking front differential?

If its the new AWD system you may have the exploding plastic roller cage syndrome going on.

 

Yes - the speedometer works just fine. what is exploding plastic roller cage syndrome? lol - that sounds expensive!

 

Here is a few dozen post you can read about the problem. ATVConnection.com ATV Enthusiast Community - Search Results

The Roller cage is a little pricy $200 but I hear its not a bad job to change out.