My clymer manual says you can use transmission fluid "Type F". But never tried it.

 

I made an error earlier. He didnt put grease in the bearings, he did in fact put type "F" transmission fluid in the hubs.. I took the plug out of the hub and it had transmissionfluid in it. I questioned him as to what type and he stated that it was type F. Now for the fun part of finding the problem lol.. I purchased a Polaris service manual from a friend for the 03 Sportsman. Now i can get to the bottom of the problem. I'll let you know what i find.. Thanks TLC and everyone for your help. Sincerely appreciate it.

 

When you changed AWD switch with another,did that one light up? The light has to come on for the AWD to work,its part of the circuit. If the other swich works put did not light up ,I would quess a broken or lose wire somewhere.

 

When i replaced the switch with a known working switch (took it off of my sons Polaris) it did not light up either. I think i may have found te problem. The Magnetic coil is showing an open circuit. So, i removed the hub and found the wires in the magnetic coil are broken in a couple places. So now time to dig in the Wallet and buy new coils. Might as well replace both sides while i have it down.

 

Here is a good link to help you. http://www.atvtime.com/phpBB2/viewto...003&pc_t=12521

 

Well after much Pain and Suffering of tracking down everything in the wiring Harness.. I found the Culprit... Speedo... Yeah !! Trust me it wasnt fun at all lol...
Got a new speedo and now everything works great.. How i found the problem was, after checking the wiring harness and finding no faults (with the aide of a good manual) , i contacted a friend who has an 03 Sportsman and he let me borrow his Speedo.. Tada.. everything worked... So thanks to all for all your help.. Much appreciated

 

Hope you did not pay to much just for a speedo because there is a free speedo bypass trick to get your AWD up and running like normal. http://forums.atvconnection.com/pola...ml#post2800053



It was a bad idea for Polaris to make the speedo part of the AWD system in 2000.