i have a 2000 polaris explorer 250 and the awd is intermittant. sometimes when i start it the awd light won't come on and when it is'nt on there's no awd. then sometimes when i start it the awd light is on, but if i shift it into neutral or reverse then back to high or low the light won't come back on and when that light is'nt on there's no awd.Or if i start it and the awd light is on and i switch the switch off then back on again the awd light won't come back on. the awd switch is good because i took it apart and cleaned it out and the same with the starter switch it seems to be functioning fine but this is driving me crazy, can anybody help me?

 

welcome to the forum. if your awd light is on you don't have it working? this might be becuase of either bad or low hub fluid or damaged hubs(internally). hub fluid does need to be changed once in awhile. if the awd light only comes on once in awhile when shifting between gears maybe the trans switch is messing up as well. this is to tell the bike when it's in reverse and you need the override button pushed to make the awd to work. worth a check.

 

ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

This link should be a sticky.LOL

 

i think it's an electrical problem, the battery is good, i'm wondering if it might be the front hub engagement limiter module.

 

Its the gear selector switch.

 

at one point i ran the quad without the battery connected like an idiot i listened to someone i should'nt have, and i think i damaged the LR83 limiter module. I have the polaris service manual for the xplorer and i read up on it, running it without the battery connected can blow the light bulbs and damage the module.

 

I have the same issue w my xplorer 250. Did you resolve?

 

Change the hub fluid first if you haven't done so in awhile and see if it helps. If it doesn't help, try to reground the strut coil ground wires as shown on this Sportsman 500.

 

thanks for responce. yes i did the brown/wh cluster to a common grd on the coil like vid shows. ran and tested all day long. working flawlessly. hope that is the cure. thanks

 

These thin strut awd wires in my opinion needed to be upgraded years ago,same as the thin wiring used on the efi sensors that give people fits. Glad you got you got it fixed.