I'm totally new to the forums. I have an 03 Sportsman 400. IN the past 3 months the AWD stopped working and the Speedometer stopped displaying the Speed. All it shows is 0 . I replaced the Speed sensor and the speed started working, The AWD still does not work. It does not even light up on the selector switch. I have checked the connections on the switch and it is getting power. I borrowed a working AWD switch and tried it, still nothing. Any ideas? btw the engine runs great and no problems with lights etc..

 

You have to have a working speedo for the AWD to work, or do the bypass trick to get it back.http://forums.atvconnection.com/pola...ml#post2800053

 

The speedometer now works but still no AWD. Is there some type of electrical component that tells this when to work? Another note. you dont have to press the OD button when you switch it to reverse.

 

I have a 05 and the switch in AWD position the rears have to start spinning to engage the fronts,do`nt know if Yours be the same or not????

 

Yeah this 03 is the same way. Well it was when it was working lol. The AWD switch doesnt even light up. As i stated before, i replaced the switch with a known working switch and it did not light up. I guess i need to find a wiring diagram for the 03 and start tracking it down. Was just thinking about something, Could putting regular wheel bearing grease instead of the polaris grease in the front bearings have any affect on this problem?

 

Anyone have a wiring diagram for an 03 Sportsman 400 or know of a link to one?

 

Should not be any grease in the front bearings, usesdemand drive FLUID, that could be the problem, take it apart and clean the grease out then fill the hubs with fluid at the 2 o'clock position.

 

Thanks for the info. I will try that.

 

Here is what the locking hubs look like and how they work and how to fill them and with what. If you put grease in there you have a clean out job ahead of you. ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

 

Thanks TLC for the link. Do i need to use the Polaris Demnd Drive fluid or is there something else i can put in it. Btw i wasnt the one that put grease in the hubs. I let a Supposed mech friend of mine replace the bearings..