The Polaris people who came up with this system should be,well use your imagination.I think this system kept OPT pretty busy over the years as a tech.Geez have you seen how small those coil wires are,and on a machine used off road.Shame on them I say

 

The only decent size wiring is the battery cables...

 

Okay so I got a new battery today, and the speedometer backlight, hours and miles meters work! But the needle does not. And they only work when the OFF-RUN-OFF switch is in the off position. What would cause this? And will the speedometer still control AWD correctly without the needle working? Thanks.

 

Still sounds like you have a short either in the left control switch contacts/wiring or the wiring from the switch down into the pod.

 

The AWD light still doesn't come on. Which wire should have power going to the AWD switch? And does the needle part have to work for AWD to work in the speedometer?

 

My speedo needle has not worked for years but the awd is fine.
The speedo is not the problem it is a wheel sensor called a "Hall Efect" but for $80 and the bother to change it I,m just live without it.

 

Awd indicator bulb had the same brown/white ground wire and grey power wire as the speedo and hub coils. Check the grey for power when in gear and in awd mode.If it's hot,run a jumper wire from the brown/white to another brown or frame ground to see if the indicator lights up. If the speedo still only lights up when the left control switch is in emergency off position and blanks out in the on position,then still sounds like the control switch is the problem or you may have multiple problems along with possible grounding issues from the speedo assy.

 

I took the ATV out this weekend and the AWD light started coming on when in low. I got stuck and the AWD felt like it was trying to kick in but it would just jump and make a popping noise. Never actually engaged. What does this sound like?

 

Still sounds like an intermittent short if the light came on in low range or possible that the 3 position switch on the tranny (R/N/H) could be faulty if awd only kicked in in low range. This switch also when in gear helps complete the circuit and the awd light should come on in high range also.But the popping noise could be mechanical,so you could have both an intermittent short or a gear position switch problem on the transmission, plus could have some problems in the front drive system ranging from either the front gear case,drive shaft or one or the other front hubs.Just need to eliminate one thing at a time.Switch is the back one #11 and has plastic levers that can break and have broken before,plus they've been updated. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse