What about the switch question? Would there be any way to make it work?

 

Yes,but rather than tie a red/white(aux hot wire with key on) to each gray wire to a toggle switch lug and tieing the brown wires to the other,just try rewiring the existing ground wires first. I know what your wanting to do on a toggle switch,but I would do this only as a last resort.

 

Okay thanks. But if I do have to resort to the toggle switch, should I tie the grey wire from both sides together and then to the switch, and the other side of the switch to the batter? Does that sound right? Thanks.

 

Would it be possible to make a solid hub so it's in all time 4wd?

 

NO!!! Never tie direct to the battery. There should be an unused red/white(aux wire)under the front panel that's only hot with the key on that you could jump to the toggle tied with BOTH gray wires. Then Both brown wires to the other lug. If by accident this switch was engaged at high speed,possible damage to the system or injury could happen especially if one wheel kicked in first! Try the methods on regrounding existing wires first to see if you can regain the awd switch function!

 

Okay thanks, I'm going to try all of my options first before I even consider the switch. So both brown wires need to be grounded to the frame correct?

 

Either to the frame, the coil mount,or where ever you see the most brown wires grouped together.

 

Okay thanks, what about the full time 4x4 idea?

 

All this would do is cause armature plates in the hubs to magnetize even quicker with constant current to the coils,same as if you left the awd switch on all the time which is not a good idea that many people found out. When one wheel or the other would lock in while even in two wheel drive mode it's not a good feeling! Just try the grounding method and see if it works and post back.

 

The Polaris can not be in constant 4wd , it would be like riding a ATV in full time diff lock and would be uncontrollable.
That's why its always in 2wd unless the rear wheels slip than returns into 2wd once the rear wheels regains traction. This is all done in a split second.
It would be impossible to duplicate manually.