Old Polaris Tech, I've got two older Polaris' I just bought, awd doesn't work in either one of them, so I'm reading all I can here. 98 Sportsman doesn't seem to want to fully engage in forward or reverse, you really have to push it in or it jumps back out. Wondering if this might have something to do with the awd not working, if Im not getting the shifter engaged far enough? Also, I used it to plow snow the other day, really the first time I've driven it, and a couple times when backing up something bound up and turned the wheels harder than I could straighten them. I wasn't pushing the reverse override button because I was sure awd wasn't working, but in retrospect maybe I was getting some 4wd and torque steer.

Secondly, I have an 03 Scrambler 500ho, awd doesn't seem to work but the one time I rode it I had the right front wheel lock up and slide a couple of times, luckily I was on wet leaves and didn't lose control. Sound like a hub trying to engage or something?

 

Linkage adjustment may help. have in neutral,loosen the linkage ball lock nuts at the shift box levers,remove the 10 mm bottom nuts,adjust linkage to where they drop straight into the levers and tighten all nuts.1998 model also sounds like the common problem of shift box wear along with internal shift box gear position switch. Look at this series of posts this member had on his awd problem.http://forums.atvconnection.com/pola...ml#post3225674
Could be an armature plate problem on the 2003,but change the hub fluid in ALL the machines first to see if it helps. Speedo controls the awd function internally on the 2003,but grounding issues were a problem also on the small hub coil wires. If changing oil doesn't help,look at this video. May be the solution to your problem.

 

how do you change the hub fluid? Wish that video was a little clearer, I can hear him but I cant really see exactly which wires he means. And he says to cut one, and splice all four together. Does cutting one make two of the four?

 

Think you need a manual for service.. Here's a free pdf service manual for the 98.Index of /ORV Manuals/Polaris/1996-1998 - All Models
Plus here's 5 buck one for your 2003 model.2003 Polaris Sportsman 500 Service Manual PDF Download
Plus you can always find videos on You Tube.

 

Does the light at the switch complete the 4wd circuit on a 2000 Sportsman 500, as well?

 

No,they eliminated having the light built into the awd circuit several years before the 2000 model. The gear position switches are on the transmission on the 2000 model instead of the shift box.(first year was the 99 model) Item#12 and 13.http://www.cyclepartswarehouse.com/f...2000&fveh=5519

 

Thanks again, OPT.

 

switch in gear box!!, remove gray/white wire from the AWD switch to circuit board and move over to red/white circuit board blade, now u have power to switch all the time.

 

Thank you. Sounds like a direct version of what OPT suggested. I'll try a jumper wire before I cut anything apart.

Thanks again, guys.

Once I get this sorted, then I can move onto trying to find out why I have no low range. I'm wondering if it only works if you have working 4wd. If not, I read here how to adjust the linkage. I hope it's something simple.

This machine has lots of problems. I hate when people let the "simple things" compile until their machine is a hunk of crap then sell it (to an unsuspecting, but thankfully mechanical, nimrod like me ).

 

Gear position switches were moved to the transmission beginning with the 99 models where they should have been in the first place. Gear box switches were always a problem.