[newfielander]

Guys, can anyone tell me if the wire that goes in through the front end of a 2014 Polaris 550 X2 Sportsman is a single wire or a double wire? I damaged the wire where it enters the front-end gear case, and the exposed wire is all pressed together, (that's the best way I know to explain it.) It's hard to see if there are actually 2 wires that actually travel together or not.

 

[parshath77]

Do you have a picture?

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[newfielander]

Do you have a picture?

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[latebird]

There is two wires - a power wire and ground wire

 

[newfielander]

Thanks, thats going to be tough to fix, any suggestions?

 

[latebird]

Best fix is to remove the front gearcase and install a new cover with coil assembly - #1 @ $505.00 USD

 

[newfielander]

Wow, thats not good news........especially since this was a mistake by someone else trying to help. (hit the wire by mistake) . Ok thanks

 

[newfielander]

There is two wires - a power wire and ground wire

Correct me if I am wrong but these wires are the wires that send power to the magnet inside the front diff when the switch is on, but what I don't understand is I still have 4-wheel drive even though these 2 wires have now meshed together from the damage. I did lose 4-wheel drive at first due to the naked wire touching the sides of the front diff, so I just pulled all the wires away from the side of the front diff and made sure no wires were touching the sides of the front diff, and changed a blown fuse and to my surprise, I have 4-wheel drive. But I do not have any symbol of 4x4 drive on my display.

 

[latebird]

Correct me if I am wrong but these wires are the wires that send power to the magnet inside the front diff when the switch is on, but what I don't understand is I still have 4-wheel drive even though these 2 wires have now meshed together from the damage. I did lose 4-wheel drive at first due to the naked wire touching the sides of the front diff, so I just pulled all the wires away from the side of the front diff and made sure no wires were touching the sides of the front diff, and changed a blown fuse and to my surprise, I have 4-wheel drive. But I do not have any symbol of 4x4 drive on my display.

That's commonly known as blind luck - milk it until it quits altogether then get it fixed right.

 

[newfielander]

That's commonly known as blind luck - milk it until it quits altogether then get it fixed right.

This damaged wire as seen in my attached picture is part of a plugin that has 4 wires, so 2 more enter the gear case at the top/backside from what i can see. So right now my switch does not work, but my bike is always in 4-wheel drive. The other 2 wires, does anyone know the purpose of them?

 

[latebird]

Your ATV apparently has Turf Mode or 4x4 LOCK - I'm not sure without looking at the wiring schematic - what's the VIN so I can get the correct schematic?

 

[newfielander]

4XATN5EA3EA096390.
It has turf and 4x4, then also on the switch it has the third option of having the front locked in for downhill. I'm guessing the purpose for this is to keep the front end engaged when going downhill, the engine brake works better, instead of just the back tires to slow the bike down, the front is helping as well.
Maybe I should have clarified from the start of this post but my ATV has several issues which might all be related, Sometimes I have 4-wheel drive perfectly, then sometimes only in reverse and not in forward, then sometimes it's vice-versa. Then sometimes I have EPS, but most times it's not working. Then my engine light comes on sometimes, and then I might go start the bike, and it's not on. Is it possible this is all electrical related?

 

[newfielander]

4XATN5EA3EA096390.
It has turf and 4x4, then also on the switch it has the third option of having the front locked in for downhill. I'm guessing the purpose for this is to keep the front end engaged when going downhill, the engine brake works better, instead of just the back tires to slow the bike down, the front is helping as well.
Maybe I should have clarified from the start of this post but my ATV has several issues which might all be related, Sometimes I have 4-wheel drive perfectly, then sometimes only in reverse and not in forward, then sometimes it's vice-versa. Then sometimes I have EPS, but most times it's not working. Then my engine light comes on sometimes, and then I might go start the bike, and it's not on. Is it possible this is all electrical related?

I also should mention sometimes it will start perfectly other times when I turn the key you would think the battery was dead, but cross out the starter solenoid and it starts perfectly! There is also a second code I'm getting on the display.

 

[latebird]

Yes - you have multiple electrical faults - you should take it to the dealer and have them correct all the malfunctions - to save time and money, you might pull the front gear case and replace the cover with the turf solenoid, diff lock and Hilliard clutch actuator. That will cost over $600, but save you probably over $1000.

 

[FPD218]

All Wheel Drive Control Circuit	Voltage Above Normal, Or Shorted To High Source	520207	3

 

[newfielander]

Guys, I figured out there was a wire broken up tight to the hand brake handle,(I now have it fixed) and of course, a Polaris has to have the brake on to start. So my bike now starts fine, but I still have 4x4 and EPS issues. I pulled the front end out and took it all apart and cleaned it completely and replaced the small split pin on the ring gear assembly and also put another Output Cover Assembly, Part 3235164 which has the 4WD magnetic coil on the inside. I didn't see any other broken parts inside so I put it back together again and I watch a video on YouTube,

showing how I can test the front end before I go through the work of putting it back into the bike, starting at the 7:21 marker. But according to this my 4x4 still doesn't work. I decided to test the wires that go to the front end, 2 wires for regular 4x4 and 2 wires for the ADC. Now my question is when the 4x4 switch is off, and I put the multimeter on the plugin, there shouldn't be any power showing, should it? But on my bike, it's showing the voltage of the bike if the switch is on or off. My understanding was when I turned the 4x4 switch on, power should then go to the magnetic coil. and when I turned it off the magnetic coil shouldn't be magnetized. Can someone correct me if I'm wrong but it seems that there is always power going to my front end but yet I don't have any 4x4. I appreciate any comment. Everything helps!!