I have a 2002 scrambler, when I go to turn the AWD switch on it will not kick in most of the time. Then I got to pull it in my garage, take off the throttle assembly, move it around, kick it in neutral reverse drive several times until the AWD light lights up then I can drive in AWD And I can ride in it for about 30 minutes or until I shut it off. Is there a certain way to kick it on that I'm missing? Please let me know ASAP.

 

When it's turned on and the rear wheels start to spin the front end should lock in immediately then unlock when the rear end gets traction again. No certain way to do anything except don't push the button when the rear is spinning or the front end will blow up.

 

My problem is with it not engaging at all. The switch will be on and it will not engage unless I take the screws out of the throttle case and move the wires around... then it will engage for about 30 minutes and then go out again

 

Problem may not be entirely in the awd switch,but could be a faulty ground problem further down that a lot have had. These thin brown ground wires and long travel to the hubs can cause intermittent action. You can do as many have done and have a larger,better ground and see if that helps. If it doesn't help then it may take a new throttle control as the awd switch(if shorting out) can't be bought separately.This is what people have done to regain awd.Video is on a Sportsman 500,but the same procedure.