So I bought a Scrambler a couple of weeks ago and I have been fixing all the things the previous owner ignored. I took it for a test drive in a sand pit and the front wheels don't lock when I select AWD. AWD light comes on when switched on.
I did lots of reading and inspected the hubs. Replaced armature plate on one side and nothing on the other. Refilled with oil and started looking at the electrical side of things.
I tested for voltage at the hub wiring and only got 10.4V. I did however get the correct ohm reading of 25.
I repaired some splices at the ignition and got 11.3V now at the hubs.
I also cleaned the AWD switch and everything looks good.
Where could I be losing volts and would it prevent AWD from working?

 

Awd coils can can get hot and weaken over time(especially if hub fluid isn't changed regularly) same as armature plates can magnetize if the awd switch is left on constantly. If the voltage on the coils got better when you messed with the ign switch wiring,then it still could be a wiring problem or the coil even with 25 ohms resistance reading. Plus check the coil sleeve and strut inner pole for wear/grinding. This too can stop the coil from pulling the armature plate back allowing awd operation. OPT

 

Thanks for your reply!
I'm going to check the electrical tonight to try to at least have battery voltage to the coils before I go back into the hubs. The previous owner has removed the reverse limiter and messed with the brown/white wiring at the hub connectors. Lots of electrical tape!
Also I can't test the awd right now as I am waiting on a pulse coil to arrive.

 

Does the speedo work? The speedo must work to have AWD on a Polaris.

 

The bike does not have a speedo. Only wiring I can see for a speedo is a wheel speed sensor currently disconnected and going nowhere.

 

Ok so I repaired the wiring and achieved 12.7v to the coils. I still don't have a running bike as I am waiting on a pulse coil so I tested the awd by rotating the rears by hand and the AWD did not work.
So I stripped down both hubs and investigated. Both coil poles were well out of adjustment so I got them to spec. Also there was some scuffs on the back of one clucths so I repaired that. New armature plates on both sides and reasembled with OEM oil. Put her in 'D', AWD on, Ignition on and rotated the rears while my buddy tried to hold the fronts and thankfully he could not. AWD working at least by the only test I could do. My coil should be here today or tomorrow and I will drive it to see if I am indeed successful.

 

Sounds like you have the awd fixed,especially since both front tires are locking in. OPT