I have a 99 and 2000 and I commend you for your simple fix and doing the math! Worked on each machine! Both machines no longer have working speedometers and have been replaced by aftermarket GPS heads. I heard that the speedometer head also houses the 'brains' for the AWD. There's a PNP chip and something else that can be replaced to regain functionality but this fix is easier and more reliable. Thanks again!
I have a 97 Polaris sportsman 500 that my neighbor gave to me. It has a plow and I figured it'd be great for our property (10 acres in northern WI) I've spent quite a bit of time and money tuning it up and fixed some small issues (No charging, bad starter, bad recoil, etc) over the past couple months. It was stored in the yard uncovered for years so it needed quite a bit of TLC. The last thing is the AWD. I just cannot get it to turn on and drive the front wheels. I've replaced the magnetic coils, Armature plates, (1) of the hillard Clutches, outer seals (Poles), verified clearance between the outer/inner poles which is spot on at
When you replaced the magnetic coil did you make sure the inner ring is flush with the outer ring...all the way around? I had that issue once. If it's not perfect it loses its magnetic power. Also. I dont torque my hubs to spec. It seems like it's too tight and the hubs dont respond correctly. I just snug them up till there is a little drag. Sounds like you have power. And you grounded it. A good ground is important.
@@TitaniummanGarage I seated the magnetic coil all the way back. I then tapped on the outer sleeve flush to the inner pole. I've been focusing on the right side and last night I got out a machinist scale and shim gauges to double check. It was not perfect (But very close) I proceeded to check all the way around and had to do some minor adjustments but now it is perfect but still no 4WD. I work from home so on lunch break I'm going to go out there and experiment with a very loose setting on the spindle nut and see what happens. I was also just reading how someone had experienced the hardened sleeve in the hub assembly coming loose and spinning inside the hub thus acting like no Hilliard engagement when it actually was engaged. I'll check this, too. Thanks for the quick reply! Where are you at in WI? I'm in Marinette county.
@@TitaniummanGarage I'm near Goodman. We just moved up here from the Milwaukee area. Finally can use an ATV and snowmobile from my front door. Totally awesome! Anyways, I went out to the garage and fooled around with it. The torque on the nut had no effect. I did however add 3 small pieces of small diameter fuel hose to the 3 tabs that protrude from the armature plate. My thinking is I needed more pressure on the armature against the magnetic poles. For the first time the right front wheel engaged 4wd! It was intermittent and didn't disengage well by turning off the switch. Going into reverse would disengage it. After I reassembled and added hub fluid it didn't seem to work anymore. The Hub fluid must be too slick and reduced the friction. I might fool around with the fuel hose idea a little more, maybe add a longer piece to add more pressure on the plate. Not sure how long this fix might last but the fuel hose fits perfectly in the 3 notches on the back side of the Hilliard assembly. I think the inner poles are worn down from bad wheel bearings and to fix properly will require new struts which probably won't happen on this machine. If I can get the 4WD to stick on by rigging up with something (Fuel hose) it'd be good enough to plow with. Thanks for the advice and videos!
I noticed when i jack up the Polaris and floor it the AWD kicks on when its floored but when you floor it it jerks and breaks the axel due to the AWD kicking on. the wires are still in mint condition and the reverse overide works only if you floor it to. Ive gotten stuck multiple times and it would not spin but one front tire or none of the fron tires. its a hit or miss when talking about the fourwheel drive on the ol polaris.
Hello, I have a 1997 Polaris Sportsman 500 and when it's running and I engage it into 4x4 and push the AWD button the whole machine kills. Should I change the ground wires like what happened in this video?
I’m trying to do the same but only have two grey wires. I believe it’s a 99, but mine does not have that board like yours does in the video. All I have is two grey wires and not one with a white stripe. Any help would be greatly appreciated. You are Polaris man in my book. Lol
You have the plug and play style. 2 grey wires and a ground looping to both. I would add a wire to that ground wire and connect it to the frame somewhere. Use a test light first to see if you have power to the 2 grey while in 4 wheel drive first.
First off love the videos. I do have a couple quick questions. First off can the AWD switch be lit and still be bad? What do you have your volt meter set on? Lastly where exactly is your neg volt meter attached to? Thanks
There is a chance it could be. But if you hook the volt meter set it to 20 volts. Put the black on any ground. You should be able to tell if your switch is bad.
I'm stumped, mine (1996 sportsman 500) isn't working on the right side wheel. I changed the coil, and tested it by running the atv and having the rear wheels spin. I can tell the coil is working by how strong it is. Reassembled the clutch (it's new and so is the armature plate), filled the hub with the demand drive fluid to the 3 o'clock position, I didn't use grease . Still won't work. Any ideas??? Any help would be appreciated.
I just fixed it! After 2 years of working on this on and off, the awd being the major issue, I finally fixed it today. I figured out I hadn't tightened the castle nut enough. It needed just a little resistance to help engage the clutch. Now it works!!!
Great video, thanks !...on my 2004 sportsman.500 HO, I noticed on speedo the gear indicator lights were going out...possibly fried speedo ?...would this also cause issues w my AWD ? ....thanks in advance !
Thank you for making these videos!!! I have a 2002 Scrambler 400 4x4...4x4 only works in reverse with override button pushed in. Then button is pushed in, the add light on the right control is illuminated, when I release the button, the light goes out. I'm wondering if the Trans Switch is bad? any help is greatly appreciated. Thanks!
I have a 96 Sportsman, when I test that grey connection, I'm not getting any power, and the 4x4 light never comes on and the button won't stay in, I push it in and it pops right back out. Any advice to what it could be?
I don't have that one anymore. Sometimes when I can't figure out a wire harness I will look at someone's video and pause it when it shows the wires I need to see.
2002 500 Scrambler After replacing the head, the fan is not engaging. Wire to the bottom of the radiator is hot. Suggestions besides the thermostat? Tia
I have a 2001 500 ho put new camshaft in and china 30 dollar carb. Starts right up accelerates good but won't idle no matter what I do with mixture screw. Seems to be hydrastatic locked after it's hot. Any ideas? Thanks
I would double check the valve lash. Sometimes after replacing a cam after the chain has revolved in the engine a bit it tightens more and throws off the adjustment you set. Also depends what carb you bought. I've had good and bad ones. I must have at least 10 china carbs in a box that didn't work. I use the parts to rebuild the oem carb.
Hello I have a 03 Polaris Magnum 330 feels like my right front tires locking up hard to steer feels like something is fighting any recommendations would greatly help thank you
I've got a 1993 2 stroke 350 and and it's on demand I let a friend drive it and he done something to it I found that the light was on 4x4 and I turned the switch of and now when u put in high it's like it won't pick up speed but in reverse it's fine it goes fast and now it won't turn on 4x4
I have a 1999 Polaris 500 magnam starter got water in it And frooze up changed starter-abendix and starter cylenoid went to start and only cylenoid clicked taken apart twice same thing have to start with pull rope I am 72 years old have a bad heart and towrn rotator cuff this pull starting is killing me need help any tips apreciated
Is the starter new? I'm not sure what you mean when you said you took it apart twice. So..you have power to the solinoid but not the starter. Have you tried a new battery? Sometimes the battery will read 12 volts but when you add power like lights or a starter the voltage drops and the starter won't turn. Also look for any broken wires leading up to the solinoid. It could be a weak connection in the wire harness going up to the start button. I believe it's a white wire with red line on it. I had to trace one once. It turned out the start button turned green and corroded on the inside. Not sure if that is your problem only because your solinoid is clicking telling me you have power from the start button.
You have a inner ring, then the magnetic coil,then an outer ring. Take something perfectly strait like a ruler or a piece of metal and go across the whole coil. See if the outer ring is out further than inner ring. If it's more than .001 it won't magnetize. Only the outer ring moves.
So, why are the wheels turning at idle? My guess is that the belt drags just enough on the pulleys that the tires will turn when there is nothing holding the tires? And my other question.....I thought the all wheel drive was only on demand? Or does it sense that the wheels are slipping when it's jacked up like that?
Hi, would you be able to do us a favour? We need to find out the size of the O ring that goes into the Carburettor and holds the float needle, Internal, external and Cross sectional dimension, I have been ordering through eBay and what I get do not last, they are not Viton O rings, so the fuel kills them very fast. If you know where to get the Fluorocarbon O rings, please tell us, and if it is hard to get them to deliver in Australia, could you buy them for us and send me about 6 of them, I will reimburse you quickly. Regards, Franklin
I tested my wires on my Polaris 500 magnum. The gray wire has 12 volts. Then for the heck of it, I tested the brown and it got 12 volts as well. Brown is ground isn't it? The 4wd doesn't work but can't figure out why I would have 12 volts to the brown wire.
I have the same problem the wires on mine are shorted out on both sides between where they split off to go to the hubs and the hubs. It doesn't make sense to me why the would both short out. Just got it but someone else unhooked the ground to keep from arking out
@@austinjackson8248 I got my rig figured out. My speedometer wasn't grounding out the 12v to the coil. This is a known issue with these speedometers. All I did was cut the two wires that goes into the speedometer that are grounds and wire them together. You can still use all the AWD switches as usual and doesn't harm anything. The two wires you cut are the brown with the white stripe and the solid brown. Those are your grounds that need to be tied together. Mine has worked perfectly since doing this. Good Luck.
Hey mate. I’ve been trying to find a work around and I’m getting stumped. I have a 2003 sportsman, and Polaris changed the wiring harness around. 1st, they omitted Gray with white, and I can’t find a similar line anywhere on the harness. And 2nd, I seem to have power to the AWD wires whether I’m in gear or not. I have AWD in H & L, but can’t get it to kick in while I’m in reverse. My override button does nothing. I wanted to omit it so when I plow this year, I wouldn’t need to press it to keep my AWD in reverse. Wisconsin winters and all. I’ve been looking at my wiring diagram to see if there was a spot I could splice into where I wouldn’t need to hit the override button, and bypass the tranny switch, as you did, but I’m not seeing a way. Do you have any ideas?
So, I found the gray with the orange stripe is what comes off of my override switch, but it toggles between my miles, tach, hour meter and voltage. My switch is not working, because I've never been able to toggle between anything. But when I ground out that wire, my AWD does work in Reverse now. But if I leave it grounded, I get a flashing check engine icon on my speedo. If I just touch the wire to ground, I toggle between my choices on my speedo. I'm thinking to hook it up to a toggle switch, so I can turn it on when I want, but hopefully won't give me any issues. What do you think?
I would have to look at a 03 wire diagram.Did you see my video on the bypass tranny switch? Without looking at the wire diagram it could be a ground issue. I would double check your grounds. make sure any wires are not touching that shouldn't be that are hot. Is that white wire you spoke of have power to it?
I did watch that video. But there is no gray with white stripe in my harness at all. The 03 has a multi function override button, not just AWD engagement. So to me, it does not seem as straight forward as giving power to it, or even grounding it out, if I understand the wiring diagram correctly. I was hoping you had come across this one before. I’ll rewatch your video on that 700, as that was the same year, but I don’t remember if they had the same functionality in the override switch on that model.
@@michaelchaoticreason5059 I was just about to ask. yes the 700 does have multi function. I've been working on so many of these I forgot how the 03 was.
@@TitaniummanGarage . I thought I had watched the video on the 700, but I guess I didn't. On my 500, there were jumper wires on my 4 wheel drive plugs. They looked like factory wires, but there was a jumper from ground to ground and from live to live. I didn't know which to splice into, so on my 500, and I actually saw in your 700 video as well, there is a grey with an orange stripe that comes off of the override button. I cut that and hooked it up to a toggle switch and grounded out the other side of the switch. It solved my issue, and if I just switch the toggle on and off, without being in AWD, it toggles the info on my speedo too! But grounding out the grounds probably would've been a lot simpler... ;) Thanks for all your help.
Check the switch on the transmission. It could be bad. Also is your shift linkage good? Does it go in reverse and forward fine? Sometime if it's not all the way in reverse, the switch won't engage on transmission. And make sure you press the override switch. sometimes that's the culprit too.
Have zero power at all. No lights no dash no 4x4. Can only start by pull cord 02 sportsman 400. Worked fine yesterday. All take ground of some wire unplugged? Any ideas??
It starts..so that rules out any kill switch issues. I would start from the battery and work your way up. Battery charged, check connection to starter solenoid sometimes it's a bad ground, loose wire. You almost need a voltage meter to check the rest. It's not an easy answer without testing anything. Make sure your battery ground wire isn't loose or corroded. It could be a number of things.
Titaniumman Garage has digital odometer only. Nothing electrical works. Cant start with starter but can turn off. No front light or break lights. No gear indication light, no 4x4. Will dig into some more shortly. Too damn cold to work on the right now.
@@mjjack7 Pull the plugs going to the start button/kill switch. I had one like that. same issue. the plug wires turned green and wouldn't start. dash wouldn't light up or lights. There should be 2 plugs. I cleaned mine with a cup of vinegar and a teaspoon of salt. let it soak for 15 minuets. It takes the green crap off. unhook battery first. Try adding another ground wire somewhere if you can. If wires are green it means bad ground.
It could be 2 things. Either there is constant power to the magnetic coils or there is no hub fluid in it and hillard clutch is froze. Try driving in reverse to get it to unlock.
![VENEZUELA vs. ARGENTINA [1-1] | RESUMEN | ELIMINATORIAS SUDAMERICANAS | FECHA 9](http://i.ytimg.com/vi/SJfoPdeOPCQ/mqdefault.jpg)
I have a 99 and 2000 and I commend you for your simple fix and doing the math! Worked on each machine!
Both machines no longer have working speedometers and have been replaced by aftermarket GPS heads. I heard that the speedometer head also houses the 'brains' for the AWD. There's a PNP chip and something else that can be replaced to regain functionality but this fix is easier and more reliable. Thanks again!
Right on! Sometimes you have to take a step back and think about how the wires go...and make adjustments.
Hey TG, buy some cheap squeeze bottles for like ketchup/mustard at restaurants. Put your ATF in one, label it. Funnel and juice in one bottle.
I have a 97 Polaris sportsman 500 that my neighbor gave to me. It has a plow and I figured it'd be great for our property (10 acres in northern WI) I've spent quite a bit of time and money tuning it up and fixed some small issues (No charging, bad starter, bad recoil, etc) over the past couple months. It was stored in the yard uncovered for years so it needed quite a bit of TLC. The last thing is the AWD. I just cannot get it to turn on and drive the front wheels. I've replaced the magnetic coils, Armature plates, (1) of the hillard Clutches, outer seals (Poles), verified clearance between the outer/inner poles which is spot on at
When you replaced the magnetic coil did you make sure the inner ring is flush with the outer ring...all the way around? I had that issue once. If it's not perfect it loses its magnetic power. Also. I dont torque my hubs to spec. It seems like it's too tight and the hubs dont respond correctly. I just snug them up till there is a little drag. Sounds like you have power. And you grounded it. A good ground is important.
@@TitaniummanGarage I seated the magnetic coil all the way back. I then tapped on the outer sleeve flush to the inner pole. I've been focusing on the right side and last night I got out a machinist scale and shim gauges to double check. It was not perfect (But very close) I proceeded to check all the way around and had to do some minor adjustments but now it is perfect but still no 4WD. I work from home so on lunch break I'm going to go out there and experiment with a very loose setting on the spindle nut and see what happens.
I was also just reading how someone had experienced the hardened sleeve in the hub assembly coming loose and spinning inside the hub thus acting like no Hilliard engagement when it actually was engaged. I'll check this, too.
Thanks for the quick reply! Where are you at in WI? I'm in Marinette county.
@@anthonyg6221 I have a cabin near high falls. My shop is in Sheboygan
@@anthonyg6221 Oh..if the nut is loose. That is correct. The hillard wont engage
@@TitaniummanGarage I'm near Goodman. We just moved up here from the Milwaukee area. Finally can use an ATV and snowmobile from my front door. Totally awesome! Anyways, I went out to the garage and fooled around with it. The torque on the nut had no effect. I did however add 3 small pieces of small diameter fuel hose to the 3 tabs that protrude from the armature plate. My thinking is I needed more pressure on the armature against the magnetic poles. For the first time the right front wheel engaged 4wd! It was intermittent and didn't disengage well by turning off the switch. Going into reverse would disengage it. After I reassembled and added hub fluid it didn't seem to work anymore. The Hub fluid must be too slick and reduced the friction. I might fool around with the fuel hose idea a little more, maybe add a longer piece to add more pressure on the plate. Not sure how long this fix might last but the fuel hose fits perfectly in the 3 notches on the back side of the Hilliard assembly.
I think the inner poles are worn down from bad wheel bearings and to fix properly will require new struts which probably won't happen on this machine. If I can get the 4WD to stick on by rigging up with something (Fuel hose) it'd be good enough to plow with.
Thanks for the advice and videos!
Great video, man! Very helpful. Thanks!
Thanks again for this vid. my 4x4 not engaging, ll go through electrical and fluid, hopefully it works.
I noticed when i jack up the Polaris and floor it the AWD kicks on when its floored but when you floor it it jerks and breaks the axel due to the AWD kicking on. the wires are still in mint condition and the reverse overide works only if you floor it to. Ive gotten stuck multiple times and it would not spin but one front tire or none of the fron tires. its a hit or miss when talking about the fourwheel drive on the ol polaris.
Hello, I have a 1997 Polaris Sportsman 500 and when it's running and I engage it into 4x4 and push the AWD button the whole machine kills. Should I change the ground wires like what happened in this video?
I’m trying to do the same but only have two grey wires. I believe it’s a 99, but mine does not have that board like yours does in the video. All I have is two grey wires and not one with a white stripe. Any help would be greatly appreciated. You are Polaris man in my book. Lol
You have the plug and play style. 2 grey wires and a ground looping to both. I would add a wire to that ground wire and connect it to the frame somewhere. Use a test light first to see if you have power to the 2 grey while in 4 wheel drive first.
First off love the videos. I do have a couple quick questions. First off can the AWD switch be lit and still be bad? What do you have your volt meter set on? Lastly where exactly is your neg volt meter attached to? Thanks
There is a chance it could be. But if you hook the volt meter set it to 20 volts. Put the black on any ground. You should be able to tell if your switch is bad.
I'm stumped, mine (1996 sportsman 500) isn't working on the right side wheel. I changed the coil, and tested it by running the atv and having the rear wheels spin. I can tell the coil is working by how strong it is. Reassembled the clutch (it's new and so is the armature plate), filled the hub with the demand drive fluid to the 3 o'clock position, I didn't use grease . Still won't work. Any ideas??? Any help would be appreciated.
I just fixed it! After 2 years of working on this on and off, the awd being the major issue, I finally fixed it today. I figured out I hadn't tightened the castle nut enough. It needed just a little resistance to help engage the clutch. Now it works!!!
Great video, thanks !...on my 2004 sportsman.500 HO, I noticed on speedo the gear indicator lights were going out...possibly fried speedo ?...would this also cause issues w my AWD ? ....thanks in advance !
Same
Thank you for making these videos!!! I have a 2002 Scrambler 400 4x4...4x4 only works in reverse with override button pushed in. Then button is pushed in, the add light on the right control is illuminated, when I release the button, the light goes out. I'm wondering if the Trans Switch is bad? any help is greatly appreciated. Thanks!
Try pushing the override button in forward gear. It does sound electrical.
If it’s only doing that in reverse, it’s working correctly. AWD will only work in reverse with the button pushed. Very annoying when plowing.
Thank you for the great informative video!!
Excellent Information. Thank you so much!
You bet!
I’m having the same issue but can’t really tell which wires your talking about
Okay I’ll check my hubs because I don’t have the 4x4 working in front both wheels don’t spin while engaged
Is it a 400 or 500?
i use squirt can marked atf for polaris only for filling
Mine is stuck in 4x4 any suggestions?
I have a 96 Sportsman, when I test that grey connection, I'm not getting any power, and the 4x4 light never comes on and the button won't stay in, I push it in and it pops right back out. Any advice to what it could be?
Its probably shot. You might want to replace the button
My Polaris is just like this one can I get a few pics of wiring in the front to make sure mine is write
I don't have that one anymore. Sometimes when I can't figure out a wire harness I will look at someone's video and pause it when it shows the wires I need to see.
2002 500 Scrambler After replacing the head, the fan is not engaging. Wire to the bottom of the radiator is hot. Suggestions besides the thermostat? Tia
ruclips.net/video/d9jZUhO1LJ0/видео.html
I have a 2001 500 ho put new camshaft in and china 30 dollar carb.
Starts right up accelerates good but won't idle no matter what I do with mixture screw.
Seems to be hydrastatic locked after it's hot.
Any ideas?
Thanks
I would double check the valve lash. Sometimes after replacing a cam after the chain has revolved in the engine a bit it tightens more and throws off the adjustment you set. Also depends what carb you bought. I've had good and bad ones. I must have at least 10 china carbs in a box that didn't work. I use the parts to rebuild the oem carb.
Thank you for you’re help 👍🏼
Hello I have a 03 Polaris Magnum 330 feels like my right front tires locking up hard to steer feels like something is fighting any recommendations would greatly help thank you
I had similar problems. Change your hub oil. Worked for me
I have this same problem and am having a hard time figuring out why
My wheels pull also. Just back the quad up a bit and the wheels seem to release again. 2001 Sportsman
That is the best looking bird nest! My 2000 Predator all time 4x4 2 stroke, looks like that, scary to 99% folks, good job Polaris!
TG
I’ve been guessing you’re in WI,
Sound exactly like Rob, who runs the KEGV airport!
I Heard I have a twin running around. Lol.
@@TitaniummanGarage Hi my friend has a 500 sportsman, does the Drive Shaft have to run even in 2 x4 ??
@@renegade9758 Yes. depending on what year.
@@TitaniummanGarage xplorer 1997
@@TitaniummanGarage he is Jack on blocks the wheels in the void the propshaft does not turn in 2x4 and no longer in 4x4
It is a 90 it runs but give it gas it bulgs out ?
I've got a 1993 2 stroke 350 and and it's on demand I let a friend drive it and he done something to it I found that the light was on 4x4 and I turned the switch of and now when u put in high it's like it won't pick up speed but in reverse it's fine it goes fast and now it won't turn on 4x4
Thank you for the video
I have a 1999 Polaris 500 magnam starter got water in it And frooze up changed starter-abendix and starter cylenoid went to start and only cylenoid clicked taken apart twice same thing have to start with pull rope I am 72 years old have a bad heart and towrn rotator cuff this pull starting is killing me need help any tips apreciated
Is the starter new? I'm not sure what you mean when you said you took it apart twice. So..you have power to the solinoid but not the starter. Have you tried a new battery? Sometimes the battery will read 12 volts but when you add power like lights or a starter the voltage drops and the starter won't turn. Also look for any broken wires leading up to the solinoid. It could be a weak connection in the wire harness going up to the start button. I believe it's a white wire with red line on it. I had to trace one once. It turned out the start button turned green and corroded on the inside. Not sure if that is your problem only because your solinoid is clicking telling me you have power from the start button.
Also check your ground wire.
When you are referring to checking the spacing of the coil and the magnet with .001 feeler gauge, can you explain better how to check this?
You have a inner ring, then the magnetic coil,then an outer ring. Take something perfectly strait like a ruler or a piece of metal and go across the whole coil. See if the outer ring is out further than inner ring. If it's more than .001 it won't magnetize. Only the outer ring moves.
I have the wires down on the bottom of the strut usually break in cold weather on me on the awd
Seen that alot. Sometimes you get lucky and can reconnect them.
So, why are the wheels turning at idle? My guess is that the belt drags just enough on the pulleys that the tires will turn when there is nothing holding the tires? And my other question.....I thought the all wheel drive was only on demand? Or does it sense that the wheels are slipping when it's jacked up like that?
The second option
@@TitaniummanGarage what do you mean by the second option? I was asking two different questions
@@adamr8628 It senses when its slipping. your belt could be too tight or idle too high. Thats why the wheels are turning
Have you found a aftermarket bulb for the AWD indicator?
No. I never replaced one.
if the speedometer don't work the 4x4 wont ether right?
Awesome vid and edits and filming and bike
Thanks man!
Hi, would you be able to do us a favour? We need to find out the size of the O ring that goes into the Carburettor and holds the float needle, Internal, external and Cross sectional dimension, I have been ordering through eBay and what I get do not last, they are not Viton O rings, so the fuel kills them very fast. If you know where to get the Fluorocarbon O rings, please tell us, and if it is hard to get them to deliver in Australia, could you buy them for us and send me about 6 of them, I will reimburse you quickly.
Regards,
Franklin
Nicely done!
I tested my wires on my Polaris 500 magnum. The gray wire has 12 volts. Then for the heck of it, I tested the brown and it got 12 volts as well. Brown is ground isn't it? The 4wd doesn't work but can't figure out why I would have 12 volts to the brown wire.
I have the same problem the wires on mine are shorted out on both sides between where they split off to go to the hubs and the hubs. It doesn't make sense to me why the would both short out. Just got it but someone else unhooked the ground to keep from arking out
Sorry I was wrong it is supposed to have 12v until it actually becomes the ground I don't fully understand why but my dad is an electrician.
@@austinjackson8248 I got my rig figured out. My speedometer wasn't grounding out the 12v to the coil. This is a known issue with these speedometers. All I did was cut the two wires that goes into the speedometer that are grounds and wire them together. You can still use all the AWD switches as usual and doesn't harm anything. The two wires you cut are the brown with the white stripe and the solid brown. Those are your grounds that need to be tied together. Mine has worked perfectly since doing this. Good Luck.
I have a 98 that's in 4wd with the switch on or off. Any ideas would be appreciated
Change the hub fluid. Drive in reverse with the switch off. Sometimes the hillard clutch sticks and won't disengage,
Hey mate. I’ve been trying to find a work around and I’m getting stumped. I have a 2003 sportsman, and Polaris changed the wiring harness around. 1st, they omitted Gray with white, and I can’t find a similar line anywhere on the harness. And 2nd, I seem to have power to the AWD wires whether I’m in gear or not. I have AWD in H & L, but can’t get it to kick in while I’m in reverse. My override button does nothing. I wanted to omit it so when I plow this year, I wouldn’t need to press it to keep my AWD in reverse. Wisconsin winters and all.
I’ve been looking at my wiring diagram to see if there was a spot I could splice into where I wouldn’t need to hit the override button, and bypass the tranny switch, as you did, but I’m not seeing a way.
Do you have any ideas?
So, I found the gray with the orange stripe is what comes off of my override switch, but it toggles between my miles, tach, hour meter and voltage. My switch is not working, because I've never been able to toggle between anything. But when I ground out that wire, my AWD does work in Reverse now. But if I leave it grounded, I get a flashing check engine icon on my speedo. If I just touch the wire to ground, I toggle between my choices on my speedo. I'm thinking to hook it up to a toggle switch, so I can turn it on when I want, but hopefully won't give me any issues. What do you think?
I would have to look at a 03 wire diagram.Did you see my video on the bypass tranny switch? Without looking at the wire diagram it could be a ground issue. I would double check your grounds. make sure any wires are not touching that shouldn't be that are hot. Is that white wire you spoke of have power to it?
I did watch that video. But there is no gray with white stripe in my harness at all. The 03 has a multi function override button, not just AWD engagement. So to me, it does not seem as straight forward as giving power to it, or even grounding it out, if I understand the wiring diagram correctly. I was hoping you had come across this one before. I’ll rewatch your video on that 700, as that was the same year, but I don’t remember if they had the same functionality in the override switch on that model.
@@michaelchaoticreason5059 I was just about to ask. yes the 700 does have multi function. I've been working on so many of these I forgot how the 03 was.
@@TitaniummanGarage . I thought I had watched the video on the 700, but I guess I didn't. On my 500, there were jumper wires on my 4 wheel drive plugs. They looked like factory wires, but there was a jumper from ground to ground and from live to live. I didn't know which to splice into, so on my 500, and I actually saw in your 700 video as well, there is a grey with an orange stripe that comes off of the override button. I cut that and hooked it up to a toggle switch and grounded out the other side of the switch. It solved my issue, and if I just switch the toggle on and off, without being in AWD, it toggles the info on my speedo too!
But grounding out the grounds probably would've been a lot simpler... ;) Thanks for all your help.
Thanks,
One question : can l test spark without battery and key harness?
No
When I flip my switch on my 99 magnum, the front axles still spin but my wheels don’t, could that still be an electrical issue or is that Machanical?
It could still be both. I would start with electrical, then check the clutches.
@@TitaniummanGarage thanks for the advice I’ll keep you posted on the results I find
I have a polaris sportsman 500 model 2008 and I discovered that it does not engage 4 × 4 in reverse. What could he have?
Check the switch on the transmission. It could be bad. Also is your shift linkage good? Does it go in reverse and forward fine? Sometime if it's not all the way in reverse, the switch won't engage on transmission. And make sure you press the override switch. sometimes that's the culprit too.
@@TitaniummanGarage
Thanks for the reply! I admit I didn't know how to press the yellow button. I wish you strength in everything you do!
Have zero power at all. No lights no dash no 4x4. Can only start by pull cord 02 sportsman 400. Worked fine yesterday. All take ground of some wire unplugged? Any ideas??
It starts..so that rules out any kill switch issues. I would start from the battery and work your way up. Battery charged, check connection to starter solenoid sometimes it's a bad ground, loose wire. You almost need a voltage meter to check the rest. It's not an easy answer without testing anything. Make sure your battery ground wire isn't loose or corroded. It could be a number of things.
Wait. You have the digital dash right? If the speedo is shot the 4x4 won't work.
Titaniumman Garage has digital odometer only. Nothing electrical works. Cant start with starter but can turn off. No front light or break lights. No gear indication light, no 4x4. Will dig into some more shortly. Too damn cold to work on the right now.
@@mjjack7 Pull the plugs going to the start button/kill switch. I had one like that. same issue. the plug wires turned green and wouldn't start. dash wouldn't light up or lights. There should be 2 plugs. I cleaned mine with a cup of vinegar and a teaspoon of salt. let it soak for 15 minuets. It takes the green crap off. unhook battery first. Try adding another ground wire somewhere if you can. If wires are green it means bad ground.
I thought it was special fluid for the front hubs??
You can use ATF as a substitute. It works just as well.
Will a bad muffler bearing keep it from starting?
Why can't I go backwards when I'm in awd
Cuanto voltaje debe de bajar a alas bobinas ?
12 volts should be at the coils
@@TitaniummanGarage Amigo los cables que bajan deben ser corriente ? o corriente y tierra ?
@@fernandoperez6166 The Grey wire is power 12 volts. The brown wire is ground
Check out this video. It will explain it better. ruclips.net/video/Kv38NeLpHO0/видео.html
I'm using a translator to read what you are saying. So where are you from?
Mine won’t go into 4wd in reverse even if I press the override button.
Check your wiring by the shifter. Clean all terminals for the 4x4 wires. It sounds like an electrical problem. It's just a matter of hunting it down.
@@TitaniummanGarage Thanks!
Turned out to be the purple wire was unplugged. 4wd works perfectly now in forward and in reverse with the override switch pressed!
Wonder if that hub is related to my wife.. all dried up..
lol
Faulty wire connection's
Mine won’t disengage
It could be 2 things. Either there is constant power to the magnetic coils or there is no hub fluid in it and hillard clutch is froze. Try driving in reverse to get it to unlock.
That wire bundle looks like a rat's nest
Hilliard not hillary
Yup! I slurred. hahaha.
He corrected himself in the video🤗