Ok thanks. I'll try to figure it out tonight and ill let you know
Thanks Harley

 

There is a difference if the speedo quits or just the "Hall Effect" wheel sensor that sends a signal to the speedo. If the wheel sensor quits the awd still works but the speedo's hour meter will be the only thing on the speedo that works.

If the speedo quits you just have nothing or awd.

 

Ok the speedo works just fine but thanks

 

So my dad toqued the bolts to 12 pounds. Checked all the wiring again to the awd switch and to the hubs and there's power everywhere there. Were pretty sure it's not electrical becuase the armature plates stick to the hubs when you turn the awd switch on.

 

Have you jacked the atv up and check out the awd? This system is not a "full time" awd drive,but only kicks on when the rear tires slip in "real world" conditions. With no load at least one of the tires should turn if all is correct and the plates are pulling to the coil,torque is correct,etc. If both don't turn then you either have an electrical problem or installation problem on both sides on the roll cages,armature plates, hub torque...Plus it's rare,but hubs can be a problem,but not both of them at the same time..

 

So should I jack the entire quad off the ground to check this? We have tried just jacking the back end of the quad to see if the front tires will pull it but they don't.

 

So I jacked the entire quad off the ground. The right front tire will spin while in AWD but I can stop it with my hand, and the left front tire doesn't spin at all?

 

Ok then,you know now which wheel is the worst,but sounds like you need to go back through both! Just retrace your steps on electrical connections on down to the coil and hub sleeve and make sure the outer hub sleeve is even with the inner pole of the strut(where the coil slips on) and NO damage to either one.These two places are where the armature plate contacts.If the sleeve or inner pole has any wear or too much gap you can have intermittent or no awd!!! Just use a straight edge on the sleeve and inner pole to see if they are flush with each other(either flush or max .001 clearance with a feeler gauge). Make sure the armature plate isn't damaged and that it will pull away from your hand(held about an 1/8 to 1/4" from the outer sleeve) when the awd switch is turned on and hard to remove until the switch is turned off.Check the inside of the hubs for any scoring/wear marks that would interfere with engagement. Then replace the hubs on the struts if everything is ok,torque hub nut to 15 pounds to preload the bearings,back off 1/2 turn,then torque to final 12 foot pounds.Use only Polaris Demand Drive awd fluid..Keep us updated..

 

Ok thanks I will try that

 

So we adjusted the hub sleeve and its now flush with the inner pole. Now one front wheel works in AWD but it spins even when your turn the AWD switch off.. And the other wheel still dosent work..