I just fixed gears and a chain in my trans after my bike got "borrowed real quick" and now mine is doing the same thing. 04 700 as well. 4x4 kicks in and out on or off.
I really dont want to pull the front diff if I dont need to...
FIRST check the fluid to make sure its clean/properly filled. These things are touchy if they don't have CLEAN fluid. If that's ok then I would suspect a broken cage inside the front diff. ONLY USE POLARIS DEMAND DRIVE FLUID
my old 2004 400 was doing same thing, i changed out the front diff as my buddy was parting out his wrecked sportsman, i took my original diff apart & cage was broken, roller bearings all over, broken gear teeth.
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