96 Polaris Magnum 4x4 not working in Low Gear - ATVConnection.com ATV Enthusiast Community



Polaris Discussions about Polaris ATVs.

Reply
 
Thread Tools Search this Thread
  #1  
Old 02-13-2018, 04:53 PM
Weekend Warrior
Thread Starter
 
Join Date: Aug 2017
Posts: 6
Default 96 Polaris Magnum 4x4 not working in Low Gear

Hello Oracles, I have a 96 polaris 425 magnum that I can drive in 2x4 or 4x4. The 4x4 works in High Gear but not Low. It doesn't work in reverse either but that might be normal. Can you advise me on how to troubleshoot it?
Reply With Quote
  #2  
Old 02-13-2018, 06:25 PM
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
 
Join Date: Jun 2008
Location: North Texas
Posts: 23,693
Default

Shifter probably not hitting the plunger(#14) in low position to engage awd. You can follow the gray/white wire from the shift box switch to the terminal board and move it to the red/white terminal section.That should allow awd in high range and also low. In reverse you have to press the over ride button so awd can kick in.
Attached Thumbnails
96 Polaris Magnum 4x4 not working in Low Gear-3a08e2b1bfd1a89db3d451f28b7b423f64cbf04a.png  
Reply With Quote
  #3  
Old 02-13-2018, 08:47 PM
jumbofrank's Avatar
Moto Psycho
 
Join Date: May 2008
Location: Michigan
Posts: 7,973
Default

OPT is probably right as usual. Parts would wear out in those old shift boxes and cause problems. I would try using the reverse override button in low just out of curiosity before moving the wire to the other terminal.
Reply With Quote
  #4  
Old 02-13-2018, 10:25 PM
Weekend Warrior
Thread Starter
 
Join Date: Aug 2017
Posts: 6
Default 96 Polaris Magnum 4x4 not working in Low Gear

Thank You Oracle Dudes, I will give it a try!
Reply With Quote
  #5  
Old 02-16-2018, 06:24 PM
Weekend Warrior
Thread Starter
 
Join Date: Aug 2017
Posts: 6
Default 96 Polaris Magnum 4x4 not working in Low Gear

Ok, finally got back out there. Reverse awd works fine with the overdrive and awd worked briefly in Low then stopped. Soon I noticed that there is play in the shifter and wiggling the shifter can get awd to work in Low. I have never been inside one of these shifters but is there any reason not to open it up and see if I can remove the extra play for better contact?
Reply With Quote
  #6  
Old 02-16-2018, 06:26 PM
Weekend Warrior
Thread Starter
 
Join Date: Aug 2017
Posts: 6
Default 96 Polaris Magnum 4x4 not working in Low Gear

Would that be the right way to go about addressing it?
Reply With Quote
  #7  
Old 02-16-2018, 06:57 PM
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
 
Join Date: Jun 2008
Location: North Texas
Posts: 23,693
Default

I used to go through them,replace the high dollar switches and any worn part,usually the plastic cup and springs. If you're getting a positive low range,that is no grinding,I wouldn't go through the trouble. Several ways to get awd. Jump the gray/white wire on the terminal board to the gray section and see if you have the awd light and awd. Some have just jumped a wire between the gray/white and gray wire straight out of the shift box.Plus here's how one guy did his:
"After running a hot wire to the gray wire going to the AWD switch, the 4 wheel drive worked. The only problem, it was in 4 wheel all the time. So I cut the wire and mounted a good toggle switch on flat area close to the AWD sticker. Run hot wire to switch and then to gray that goes to AWD switch. It now works as it should. When it is in AWD and the back wheels start to spin, the front wheels engage." The manual with it's wiring diagram can possibly make things easier also.You may find a better way that suits you. 1996 Polaris Magnum 4X4 Service Manual PDF Download
Reply With Quote
  #8  
Old 02-17-2018, 02:01 PM
Weekend Warrior
Thread Starter
 
Join Date: Aug 2017
Posts: 6
Default 96 Polaris Magnum 4x4 not working in Low Gear

Thank You Pardner, Im grateful.
Reply With Quote
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
1986 polaris trailboss no power Giovanni18 Polaris 5 01-01-2018 09:01 AM
Won't start when warm, instant plug fouling Simon Miller Polaris ATVs - Ask an Expert! 25 01-23-2017 03:48 PM
something is wrong with my 4x4 polarisbogger56 Polaris 5 08-16-2003 02:27 AM
Is the Polaris System a Tough One? jeffg Polaris 24 11-06-2000 09:51 PM



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -5. The time now is 07:19 AM.


We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.
 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in: