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Discussion Starter #1
I posted this under the Repair and Maintenance section, but thought I would try posting it here too. Any help that anyone can offer would be greatly appreciated. I was out on my 03 Sportsman 400 yesterday. I have been having some problems with the four wheel drive. When engaged the front right wheel would not drive. The other three would be powered, but not the front right. Later in the day, sometimes the four wheel drive would work and then sometimes it would not. Now it will not work at all. The drive shaft going to the front gearcase is spinning. So I am not sure if this is a problem with the gearcase, the hubs or the electrical switch and wiring to control the four wheel drive system. Any help would be appreciated. Thanks.
 

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I would check the wiring to the hub and change the hub fluid to start with.
 

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dump old fluid, rinse with varsol, add 1/2 new fluid run for a bit, dump, add new fluid and drive. If still does slip, or slips it occasionally, then the cage is gone or ready to go...Assuming you have voltage at connector
 

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Discussion Starter #4
Thank you very much. I changed the fluid in the hubs, and during the process I noted a broken wire on the right side. Upon further investigation, it was one for the hub. I repaired it and then checked the other side and found the same thing. Apparently the last time I was riding it, the broken wire must have been making just enough contact every now and then for it to engage the four wheel drive. Thanks again, I appreciate the help from both of you. You probably saved me a couple hundred dollars from my local dealer.
 
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