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Old 04-01-2013, 08:51 AM
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1999 Sportsman 500, AWD not working (Dummy Maneuver)!

Hello all, I am new to the site and am very impressed with the amount of good info available.

I have a question for anyone willing and able to answer.....I had a dead battery and went to place the charger cables and had them reversed. I immediately saw smoke coming from the AWD switch pod and removed the cables as quickly as I could. Needless to say I fried the switch. I replaced the entire switch assembly thinking that was where the issue was and although the switch was bad there is another problem down the line as the front wheels still do not engage when turning on the AWD. The hub coils look good visually but I want to know if anyone knows if there is a likely spot between the switch and hub coils that I could check. Any help is much appreciated.
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Old 04-01-2013, 10:04 AM
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resistance test on the coils? im not sure how many ohms there sposed to be but the manual must have that info?...and well ur diggin in the service manual look up the wiring schematic..that should help follow your wiring from switch to coil?
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Old 04-01-2013, 10:22 AM
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Thanks for responding

I am going to check the resistance on the coils tonight. I believe they should read ~25 ohms. I did not get any power readings from the switch side and thought I could rule out the coils but I will check to be sure.
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Old 04-01-2013, 11:21 AM
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u would have to have the awd switch set to on and the back wheels off the ground to similize a slipping situation to get power to the hubs. not sure your aware that the 4wd doesnt just kick in when u hit the switch? just a thought? check for power on both sides as well..
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Old 04-01-2013, 12:11 PM
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Thanks

Yeah. I had the wheels of the ground and switched to AWD in testing initially.
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Old 04-11-2013, 08:11 AM
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Temporary fix: I was able to pull the six pin connector off of the back of the speedo and jump the brown wire to the brown/white on the pig tail end and bypass the speedo. The AWD now works. Until I can get a new speedo this will work. Thanks for the help.
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