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Tried to plow snow with my "02" 400 Sportsman but it doesn't go into 4 wheel drive. Tried the switch several times to no avail. Funny thing is the reverse over-ride doesn't work either. I mean the engine doesn't sputter in reverse wether the button is depressed or not. Where to start????
 

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Welcome to the board!:med:
 

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Tks Russ .... The speedo quit working several years ago (I only ride off trail so I didn't need it). The only indicator light I get is when the bike's in neutral. All the lights, etc, work perfectly and the battery is good.
 

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Did the AWD still work after the speedo quit?? I thought you needed a functioning speedo to get AWD.
 

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Did the AWD still work after the speedo quit?? I thought you needed a functioning speedo to get AWD.
My 2002 Sportsman 400 Speedo/Odometer is not working but My 4x4 works like it's supposed to,Wonder if He is getting power to the Front Hub Cois? When is the last time hubs were serviced with the proper fluid?
 

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Did the AWD still work after the speedo quit?? I thought you needed a functioning speedo to get AWD.
My 2002 Sportsman 400 Speedo/Odometer is not working but My 4x4 works like it's supposed to,Wonder if He is getting power to the Front Hub Cois? When is the last time hubs were serviced with the proper fluid?
Tks gmiller0737 - Your post got me thinking about a possible electrical issue. Put the bike in a warm garage, got a wiring diagram and started looking. An hr or so later we found a loose connector supplying power to the front hubs. The bike is working fine now. Thanks to all who replied!!
 

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I don't want to hijack this thread, but i'm hoping someone can help me out... My 4x4 doesn't work (02 sportsman 400) but there is full power to both hubs. Armature plates and Hilliard clutches are brand new, filled hubs correctly. They magnatize as they should and have correct hub fluid. On jacks. I can stop both tires with my hand.

Another question. Where the splines / rollers on the Hilliard clutch are.. Should there be some notches on the inside of the hub for these rollers to set into when awd engages??

Because with the hub (cover?) itself off, I can see that the rollers move up when the hex nut spins on the axle... I've done the grounding re wiring, grounded the speedo out.. Awd light works, gear selector indicator works, power to the armature plates... Fully/properly magnatized ect. Someone please help :(
 
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