Hey everyone, I have a 2002 Polaris Sportsman 400. When it is in AWD, all the wheels have power except the front right. It spins freely, but does not engage when in 4WD. I changed the hub fluid but that did nothing. Thanks.

 

Pull the front panel and check that the awd connector for that side is plugged in and has power on the gray wire when in gear,key on,awd button engaged.A simple test light or meter will do. If you have power on the gray wire you can also do as some have done and make a larger common ground on the thin brown awd ground wires and see if this solves the problem. If regrounding doesn't help you can by pass the awd grounding in the speedo by jumping the brown/white wire to the brown in the speedo harness connector then check awd operation.If none of this helps you may have to tear into the hub.

 

I had this same issue it was a broken wire on the strut between the spring and the hub was rubbing on something can't remember what but crimped the wires silicone and electrical tape fixed it.