When I press awd the right hub engages left one won't,took switch apart and a couple contacts had black on them. I put some elec grease on them how do itell if they are engaging? do I have to take off the hub? the gas tank and headlight cover are off can I drive it to tell. HELP!

 

First off always change the Demand drive hub fluid if in doubt. You can pull up to a post or something firm and see if both front tires are engaging under throttle. If only one side does,check that you have voltage on the gray wire leading to the hub that's not turning.If it has voltage,may be mechanical problem that needs checking out. Could be a shorted hub coil, ground down hub coil sleeve,armature plate or even a roller cage problem. A good 5 buck manual would help the most.DOWNLOAD 1985-1995 Polaris ATV Repair Manual ALL MODELS - Download ... Plus there are several videos that can give you some basics.This is on a 500,but has the same system.

 

I followed the steps that OPT has outlined and they worked well for me. My problem turned out to be the 1/4" key-way that was sheared horizontally and allowed the roller cage to spin on the axle when engaged. Never seen a key-way shear like that before, it must have tremendous torque on it.

 

Thanks OPT and Diverod for the info. I remember the old owner saying he changed the front strut on that side and suspect he didn't put oil back in because it was empty when I checked.I think it was ran with no fluid so I don't know what I will find when torn apart.