Have been working on a newly purchased 06 Sportsman 500HO which had no AWD.

The wiring seemed messed up from the start as I thought. After searching common issues I decide to dive in and remove the Hilliard to inspect the roll cage for self destuction. At that time the two wires running the magnetic clutch had (+) on both .... ???? I thought !!!

When the clutch was apart we decided to run + - to the mag and volia perfection every thing works like it should. Now for the weird part. Which wire delivers + ve power ??? In my thought process I came up with the grey one for it originates at the AWD switch. How is the -ve introduced to the front Hilliard??? In the speedo??? This is the only place I can see an issue.

At this point I am about to simplify the AWD wiring and eliminate the AWD symbol in the speedo and have it actiate with the sliding switch and put an LED light on the dash. The other thing is the AWD symbol will flicker from time to time even when in 2x4.

Have I missed something simple ??? There isn't alot of issues with the wiring of the AWD....

 

I'm having the exact same problem with my 2005 Sportsman 700. Did you ever find out what the problem was?

 

Grey wire is the power wire and sounds like a ground problem in the coil itself,especially since its been altered by previous owner. If the wires from the switch ohm out ok,could be a short in the coil itself? OPT