Long story short... I thumbed thru tons of threads here and whatever came up on the Google.

Bought it last year, everything worked perfectly. This past summer, I was following my son on my quad and he could not make it up a hill that we normally go up (4x4 is needed.. lol) once we made it to the top, we noticed the front drive was not engaged.

Upon further inspection, it seemed as if the previous owner never changed the fluid in the front diff as the fill was dam near seized on.. got it off abd stuck finger in.. sludge came out...



Here is the list of stuff I did already :

1. Flushed the fluid in the front diff a few times, no metal chunks or shavings..
2. Checked switch, good power.
3. Checked line at connector (power when engaged and 26ohms going to diff..)
4. No noise from front diff.
5. Smashed head on front bumper... ouch!

This model does not have a speedo, wondering if it could be a speed sensor or the front diff needs to be cracked open.

Thanks in advanced..

Mike

 

most likely you have a broken roller cage in the front housing which is how the awd is engaged. pretty much made of plastic and any abuse such as switching to awd while the wheels are spinning will destroy it.