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Please help!! 2002 polaris sportsman 400 awd problem

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Old Oct 11, 2015 | 08:19 PM
  #31  
teddyb4x4's Avatar
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Thanks, grounding that brown/white wire leading to the speedo. After cutting it which end gets ground; the harness end or the end coming out of the speedometer?
Then I splice the red/white power to the cut gray wire to the handlebar AWD switch. This shouldn't magnetize would it?
 
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Old Oct 12, 2015 | 03:24 AM
  #32  
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The harness end brown/white wire ties into the brown or a good frame ground. All you're doing is bypassing the speedo as the ground circuit for the awd goes through it. Tying the red/white to the gray should power up the wire when key is on, awd switch is on. Awd indicator should light up.
 
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Old Oct 12, 2015 | 10:05 AM
  #33  
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I wouldn't want the 4x4 on at all times. Over time if the hubs get magnetized you never know when might lock in.
 
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Old Oct 12, 2015 | 11:07 AM
  #34  
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Jumbofrank; that is the whole point!
If I understand right the AWD only is powered when the hanldebar switch is on....
and my speedo will still work most of the time
 
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Old Oct 12, 2015 | 12:00 PM
  #35  
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Is cutting the brown/white wire going to disable my ground from the speedometer?
Can I just splice into it also and ground that?
 
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Old Oct 12, 2015 | 04:32 PM
  #36  
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Originally Posted by teddyb4x4
Is cutting the brown/white wire going to disable my ground from the speedometer?
Can I just splice into it also and ground that?
No cutting the brown/white won't disable the speedo. The speedo ground is the brown wire. The brown/white is ground only for the awd circuit that runs from the awd switch,then through the speedo,then goes to the coils.Easy to loose a grounding path along this route the way it was wired up from the factory,plus a common problem to loose ground path through the newer style speedos. Awd shouldn't have even gone through the speedo to begin with.
 
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Old Feb 2, 2021 | 05:48 PM
  #37  
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Originally Posted by Harley165
I just bought a 2002 polaris sportsman 400 and the AWD dosent work. I have checked the electrical going to the front hubs. It's all good there. The speedo works. I replaced the Hillard clutches. Still dosent work. Please help!

You have to confirm the Hillard engagement plate are being held by the magnetic coil when in AWD in a forward gear key on.
 
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Old Feb 6, 2021 | 05:21 PM
  #38  
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Default Couldn't fix mine with the conventional instructions on this site

Originally Posted by old polaris tech
The harness end brown/white wire ties into the brown or a good frame ground. All you're doing is bypassing the speedo as the ground circuit for the awd goes through it. Tying the red/white to the gray should power up the wire when key is on, awd switch is on. Awd indicator should light up.
My speedo is intermittent and using a voltmeter ; finally got those tiny wires to work. Sorry, can't remember what I did.
 
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