Background info I have a 1999 sportsman 500 that is having elictrical issues related to the handle bar switches.
I added heated hand grips running off the acc power sources and I have a pair or free standing lights with a direct wire to the batt.

The first problem I noticed with my 4x4 was when going in reverse and pushing override and the front wheels wouldn't engage. I then went forward and the wheels would work but still not in reverse. So i trailer it home and when i get home its working again. The next time I used my atv for plowing I bet a good 5 hours of plowing out my neighboors not a problem.

After plowing I went for a ride back to my woods which I have to go through a field to get to. I get stuck since i broke through the frozen snow so i shut off the atv and walked for a shovel came back and started it up dug it out go to drive and 4x4 is not working at all. Omg the middle of a field stuck in 2 ft of snow with 2x4 digging through the frozen layer every time i get on it so after about 2 hours of trying to turn it off/on, move it, dig it out, and tap everything i could think of I gave in and turned it off with the key. waited about 1 min and turned the key to on and pushed the kill switch boom 4x4 working crawl out and go home praying it stays on and its still working.

Anyone have any ideas I cant go through this again. Other problems Im having with the kill switch is its not turning off the atv and its also not turning the low beams on sometimes.


Sorry for the lenght but I would love to know where to start and Im too poor to pay for a shop visit.

 

dose the awd light come on when the 4x4 dont work?

 

yes took me some time in the sun to tell if it was on but its on

 

dose it have alota miles on it?

 

Its been ridden hard the guy I bought it from had a snorkel kit on it but I know him and he took good care of it.

 

Maybe drain the diff fluid and replace? Cant hurt to try.

 

i was just gona say that. it maybe evon low. but it maybe time for a hub oil change. if the light is comeing on. its in the hubs. so on last question. is it just one wheel not working in 4x4 or both?

 

Both dont work when Im having the problem

 

first change the flued in the hubs. if that dont work check the wireing for the awd. then if that dont work the hubs will need to be checked. i know theres a thread somewhere on info for the hubs.

 

Change the hub fliuds twice a year ,it takes only 20 min and a few ozs. One bottle will change the hub fliuds like 7 times or more.

Also maybe your awd button is getting sticky from the cold and frost. I think the 99 had the button which acted up so Polaris when to the slide switch.

More then you need to know about the awd link ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service