Another "4x4 not working" thread - Polaris ATV Forum
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post #1 of 17 (permalink) Old 03-29-2011, 06:47 PM Thread Starter
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Another "4x4 not working" thread

I have a 2002 Sportsman 500 HO. It was neglected by previous owner. I have torn it down and replaced all wheel bearings and seals, and I have checked all axles and shafts. I had to replace a hilliard clutch as well. I cannot figure out why my front wheels won't engage when I switch on the AWD. The speedometer works, the neutral light works, and the reverse light works. When I switch on the AWD, the AWD does not light up. If I unplug the front hubs from the wiring harness and jump power directly to these leads, the hubs engage ( while the quad is jacked up in the air with rear wheels spinning). I'm guessing my problem is electrical. Could this be caused by a faulty switch in the tranny? Any ideas where I should look? Thanks in advanvce for any help.

2002 Sportsman 500HO (camo)
1985 ATC250SX
1985 ATC250 ES (Big Red)
1984 ATC125M
1985 ATC200X
1987 TRX250 Fourtrax
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post #2 of 17 (permalink) Old 03-29-2011, 10:17 PM
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check for power going into the switch you press to activate it if you got power going in but not out id say switch is bad if no power trace the wire back and test at the next junction
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post #3 of 17 (permalink) Old 03-30-2011, 04:10 PM
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Woodsrider, To test the transmition switches disconnect the front hubs and put your meter in the plug. start the machine shift the AWD switch and put into drive. the meter will respond showing that the switches are working. I had a simular problem and followed a suggestion from the forum and burned out the front actuators. 80$ each ouch. most likely its the speedo. good luck.
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post #4 of 17 (permalink) Old 03-30-2011, 06:53 PM Thread Starter
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Quote:
Originally Posted by opie View Post
Woodsrider, To test the transmition switches disconnect the front hubs and put your meter in the plug. start the machine shift the AWD switch and put into drive. the meter will respond showing that the switches are working. I had a simular problem and followed a suggestion from the forum and burned out the front actuators. 80$ each ouch. most likely its the speedo. good luck.
Are you saying that even though my speedo works, it could causing my problem? I know that if I unplug my front hubs, there's no power going to them. The reason I asked if it could be a transmission switch, is because it looks like power comes from those switches to the AWD switch on the wiring diagram....but I am really slow with the wiring and electrical side of things, and I could have easily made a mistake while trying to figure out the wiring diagram.

2002 Sportsman 500HO (camo)
1985 ATC250SX
1985 ATC250 ES (Big Red)
1984 ATC125M
1985 ATC200X
1987 TRX250 Fourtrax
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post #5 of 17 (permalink) Old 03-30-2011, 09:45 PM
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A Power Probe works really well for these kind of problems. It is a volt meter and a powered test light all in one. You can check for power, ground or add your own. It even has circuit protection so you dont cause too much trouble if you screw up. I think your on the right track looking at the wiring diagrams. It helps if you look at the ones in the book and draw your own with only the wires you actually need. It helps keep it simple.
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post #6 of 17 (permalink) Old 03-31-2011, 02:03 PM Thread Starter
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Yeah, I think I'll draw out my own diagram like you said. It will be a lot easier to follow...good suggestion, thanks.

2002 Sportsman 500HO (camo)
1985 ATC250SX
1985 ATC250 ES (Big Red)
1984 ATC125M
1985 ATC200X
1987 TRX250 Fourtrax
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post #7 of 17 (permalink) Old 03-31-2011, 06:27 PM
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1996 sportsman 400 L does not go into awd in forward but works in reverse. any suggestions
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post #8 of 17 (permalink) Old 04-04-2011, 05:48 AM
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Help!!!

Hey I got the same problem on my 1999 sportsman 500! AWD works in reverse...." most of the time " but not while going forward. Any help here would be appreciated...Where can I get the wiring diagrams at?
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post #9 of 17 (permalink) Old 04-04-2011, 05:59 AM
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You can get one from the Clymer repair manual or you do a forum search here under repair manual and download a copy.
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post #10 of 17 (permalink) Old 04-04-2011, 06:47 AM
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wiring diagrams

The OEM wiring diagrams are so much better.
Ohm out the hubs across the brn/wht and gray wires. check to ground also. I have heard of broken wires going down to the hubs. the hubs are in series.
unplug one of the hub wiring brn/wt and gray check for battery voltage from the wiring harness. Machine in forward, 4x4 switch on key switch on. work your way back from there. you should have battery voltage on both wires they are coils so the voltage goes through them.

I think You should also get power to the hubs when you press the reverse override button. My '01 scrambler does. gets power from both places but it is a different machine.

it is simple to ohm out the transmission switches and the 4x4 switch to make sure they are good. just unplug and ohm them while changing gears. brown wire is common blue/red wire high purple wire low. check for short to ground.

WOW that speedometer is important. About every wire goes into it. It looks like the speedometer takes the place of the reverse limiter on the older models.

the red/wht wire on the speedo and the cdi and the Accessory plug should all have power then to the AWD switch. out of the AWD switch gray wire to the hubs out of the hubs brn/wht to the speedometer. you may have power when the wires are disconnected but when connected nothing. so I just unplug a little way and check voltage if you have voltage there when disconnected and no voltage connected something is causing it.

Manual says clean all connections and put a little dielectric grease on connections. I squirt a little carb cleaner in there to clean.

good luck I got my own electrical problems with these things. JH
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