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AWD Voltage

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Old Feb 21, 2022 | 04:30 AM
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Default AWD Voltage

Hello all, new to the forum. I have a 2005 Sportsman 800efi 4x4. The 4x4 is not doing so well. It started out dropping intermittently, particularly in reverse (now I can't get it to engage at all in reverse). From the searching I've done, I was about to tear into my differential (I just replaced the fluid last week) but have paused...things of note:
  • The 4wd icon lights up on the dash when the switch is on
    • When in reverse the light is off until I push the override button (then it comes on)
  • The OHMs coming from the diff is 26.5 (out of spec)
  • The voltage coming from the grey wire is low.
    • When checking voltage between the grey wire and brown wire, I get 4-9v (mostly 6-8v)
    • When probing the grey wire and the negative battery terminal I get 13v (currently on a trickle charger)
I was planning on tearing into the diff because it's one OHM out of spec and my 4x4 isn't working, but I'm thinking my very low voltage might be preventing the magnet from working correctly so I'm trying to figure that out first. I've found one skinny brown wire grounded to a bolt below the speedometer pod (cleaned up the contacts) but I can't find any other grounds around. A previous owner wired in handwarmers (don't work) and a winch (does work) so there's some extra wire hanging around. Does anyone see a problem with me just splicing into the brown/white wire (from the diff circuit) and just adding another ground? Any other thoughts?

Any/all help is appreciated. Thank you!!
 
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