If you just drove the existing sleeve in or out it may not stay there and will cause problems. This cheap pdf manual will help on the awd checkout,hilliard,armature plates,plus testing electrical problems.Well worth the 5 bucks!2002 Polaris Sportsman 400 Service Manual PDF Download

 

Ok thanls

 

Thanks for your help it was the sleeves out of alignment! One wheel still doesn't work.. But I'll figure it out!
Thanks a lot!

 

Good luck!

 

Not to pirate a thread, but I can't find the old thread. 2001 sportsman 500. Awd didn't work, did the ground bypass on the brown wires, all was good. Now I replaced the hall sensor, the speedo works, but not the AWD? Help!,,

 

Try jumping the brown/white wire at the speedo connector harness to either the solid brown wire in the harness or to a another good ground suck as the coil mount. Hopefully this should bypass the awd circuit going through the speedo. If this doesn't help check that you have power to each gray wire leading to the strut coils.

 

Fixed. Thanks again!

 

Glad you solved the problem and your speedo still works. A lot of people didn't even have that.

 

I tried the brown thin wire ground but it was a dead short. Found the swtich wire bypass instructions but wonder if I can splice into the red/white power to the speedo instead of cutting it, so I can still see my speed when it works{95% time}?
Anyone run the power to the gray/white switch? Does it disconnect the speedo? Though I doubt anyone else has the intermitent speedo!

Mines a 2000 Xpedition 425

 

Can't remember if this works on the Expedition or not,but jump the brown/white to brown in the speedo harness connector and see if you have awd and speedo also. You can run a red white wire to the gray power wire or if you have a circuit board(again can't remember on this model) you can move the gray wire to a red/white terminal and awd will be hot with the key on. Only problem on this is over time armature plates magnetize from constant 12 volts to the coil and can stick and engage awd on one wheel or the other even at low speeds.