The AWD on my '95 300 4x4 is acting up a bit. It will engage, but I need to jiggle the shifter to get the AWD light to stay on. I assume it's an issue in the shifter switch somewhere....but the service manual isn't much help.

Any ideas or suggestions?

Thanks!

 

did you try to clean the contacts of the plug end to see if there corroded and to see if it helps?

 

No...I haven't....I will give that a try though.

Thanks

 

If has trouble in hi range with awd and low range works ok,then possible switch wear in shift box. This is a common problem with the older machines. If the switch hasn't ever been changed more than likely has the plastic type flip switch. The replacement is metal and makes a lot better contact.

 

Thanks OPT. High range seems to have it worse than low. I can usually get it to stay in low range by with a wiggle or two...but I need to hold the shifter in place to get it to stay in high AWD......and I doubt that the switch has ever been changed.

 

Well....I finally got around to pulling the shifter assembly out, and I pulled the cover to take a look at the switch. The switch is a metal one, so it may have been replaced at some point. What I also found is that one of the pins on the ball end of the shifter assembly is broken off. I think this may be causing my intermittent AWD problem.

Of course, this part is no longer available from Polaris.

Edited to add:
It also appears that the switch arm is broken as well. Looks like you can still buy the switch....for an outrageous price of course. I've tried to cross reference the switch, but I can't seem to find a similar one on the internet. The markings on this switch are Electro USA 0241

 

Looked up switch at Cheap Cycle Parts (where I get my parts for my own Honda Nighthawk) and the switch is $98!! AND I know this is probably cheaper than what I can get it through Polaris! I remember when this switch was only about $30 way back when! Rule of thumb still applies: after 10 years parts will start to be NLA on certain models. Same on my 18 year old Nighthawk! Parts are beginning to be phased out even though they sold millions of em! Try searching ELECTRO SWITCH electronic products, site shows possibly what you need and dealers. Good luck OPT

 

I found a switch on ebay for a better price, and will install that when it gets here.

I wish I could find a replacement shifter arm and replace the cup bearing as well. If AWD is still a bit wonky after installing the new switch, I will just by-pass the AWD portion on the switch wiring. That way, I'll still have neutral and reverse indicators, and no more intermittent AWD.