Had something really weird happen with my 96 Xplorer 400 this past weekend.

I drove into a mud hole in 2x4 mode(high range and low speed) and got stuck. I stopped spinning the tires, pressed in on the 4x4 button to engage the front wheels and nothing . . the front wheels did not engage. Slipping her into reverse and pressing the override engaged the front wheels and got me out of the hole. Tried the hole again in high range and no front wheels. When I slipped her in Lo the front wheels engaged and out of the mud I went.

This High rage 4x4 problem disappeard in the next hole, but reappeared later in the day. Anyone have any idea what this could be?? I did Rust Check the entire bike last week . . . would this have anything to do with it??

Loyal

 

My buddy who has a 95 400 Xplorer had a similar problem. The 4wd started working randomly then not at all. It turned out to be the 4wd button on the handelbars. He replaced it and it has worked fine since.
Good Luck
Andy G

 

I ride with this guy that has a '95 Sportsman 400 and his went out in forward but always worked in reverse. I can't really remember what was wrong for sure but I think it was just the button that needed replaced. I would try that first, it is most likely the problem.

Mudman '96 Xplorer 300 4x4 Vamped (for sale)
Soon to have Magnum 500

 

Does anyone know if it is difficult to replace\clean the button?

I can spin a wrench, but if "thingies" are going to go flying all over the place when I open it up I would rather leave it to a professional.

Loyal

 

I took apart my switch on my '99 Polaris. It was full of mud, dirt, and grime. After cleaning it it functioned better/smoother and started better. A few parts fell out, and the first couple time I put it back together I had a few extra parts that I had to figure out where they went, but I got it all worked better than new now.

The '96 model has different switches, but if you get into it and have extra parts or somthing I am sure someone here can help you.

I am going to take apart the 4wd switch next, but haven't done it yet.

 

Thanks to all who replied. Just took apart the button last night and cleaned the terminals with a bit of fine sandpaper.

All that was needed was a phillips screwdriver to remove three screws and nothing went flying.

Going for another run this weekend and keeping my fingers crossed.