Polaris Scrambler 4WD repair - Polaris ATV Forum
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post #1 of 4 (permalink) Old 06-11-2019, 05:09 AM Thread Starter
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Polaris Scrambler 4WD repair

Good morning! The 4WD on my 1999 Scrambler 400 hasn't worked since I got it and I can't seem to figure out why. I've torn apart the hubs and everything seems to be in working order. Is there a way for me to check the electrical? I found a thread that went through it but what he described doesn't match up with my ATV. I also found a wiring diagram that I thought was correct but it's different too. Any help would be appreciated.
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post #2 of 4 (permalink) Old 06-11-2019, 05:59 AM
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Get all 4 wheels off the ground - start the engine, engage the AWD, set the brake, shift into forward gear, let off the brake and give it some throttle - if all 4 wheels turn it's working!

If the front wheels do not turn as the engine accelerates, find where the hub wires plug into the wiring harness, connect 12 VDC to the wires going to the hubs and try again - if the wheels turn, troubleshoot the AWD circuit - if the wheels do not turn, take the hubs apart and trouble shoot the Hilliard clutch drive components.

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1971 Triumph 650 Bonneville (has 5 original miles)
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post #3 of 4 (permalink) Old 06-11-2019, 06:53 AM Thread Starter
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I've jacked it up and know for sure that it isn't working. I'll try the 12 VDC when I get home tonight. How would I go about troubleshooting the AWD circuit? Also, there are four wires that come out of the AWD button/switch on the left handlebar and they're wrapped and when I traced them only three came out the other end. I unwrapped them and two of them are spliced together but it looks more like a factory splice. Is it supposed to be like that? Or are there supposed to be four wires connecting on both sides?
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post #4 of 4 (permalink) Old 06-11-2019, 09:04 AM
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I'm not familiar with the AWD button being on the left - every thing I has says it's on the right in the throttle housing.

I'm going to presume you have an early model as you say there is only 4 wires coming out of the throttle housing. Late model had 6.

Gray wire went to the hub coils, gray/white went to the gear selector forward wire and the black is the throttle safety switch.

If you have 12 volts on the gray wire, you either have a grounding issue or possibly a faulty hub safety module LR-83-1.
If there is not 12 volts on the gray wire, press the override switch and see if 12 volts appears.

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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