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Polaris 4x4 not engaging

Discuss Polaris 4x4 not engaging in the GENERAL DISCUSSION FORUMS forums; Howdy All, New to this technology, never posted anything before. I have a question. I have a 96 Polaris Xplorer ...


  1. #1
    Member Irunoldstuff's Avatar
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    Polaris 4x4 not engaging

    Howdy All, New to this technology, never posted anything before. I have a question. I have a 96 Polaris Xplorer 400 4x4, I use it mostly for snow plowing. The quad has lost the 4x4, I believe it's electrical, it also lost the dash indicator lights (Neutral Reverse etc). It's almost -30 so I'm not going to look at it until it warms up but I'm looking for suggestions on where to start. It went out suddenly after about 4 hours of hard plowing. 2WD can't push snow.
    Thanks



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    Re: Polaris 4x4 not engaging

    its the display/speedometer, if you power the brown with white stripe found on the column it will prove this. polaris uses the speed of the quad in its calculation for the on demand 4x4. Purchase a new one or disssasemble and clean slash dry out, that works too

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    Re: Polaris 4x4 not engaging

    I thought (can't confirm this) that the front hubs had something to do with the 4x4 operation.Magnets or something maybe i am way off.Garyese would help ya out,he is the Polaris man in these parts







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    Re: Polaris 4x4 not engaging

    probably dirty hub fluid or something wrong in the hubs.
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    Re: Polaris 4x4 not engaging

    replace the speedo

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    Member Irunoldstuff's Avatar
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    Re: Polaris 4x4 not engaging

    Hello Again, I had another quick look at it this evening. This model still has the analog speedo. All fluids are clean. I made another observation and believe I may be onto something. As mentioned in the first post, the dash lights weren't working. After driving for awile and multiple gear switches, the Neutral light is now on all the time. I'm thinking the gear selector has a switch inside and that the 4x4 won't work unless it receives proper signal from this. Any comments? Thanks for all past responses.

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    Member CrankShop910's Avatar
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    Re: Polaris 4x4 not engaging

    There is a switch in the shifter box that ties into the 4X4.
    When you in frw with the 4X4 turn on the hub coils have power going to them..
    When your in N or R the 4X4 there is no power to the coils..
    When you are in R you have to hold the override buttin to make the 4X4 work..
    If you go under the front cover there is a lot of connections there.
    The only thing that turns on the 4X4 is powering the coils in the front hubs..

    There is a eazy way to make the 4x4 stay on when the switch is on no matter what gear your in. You have to find the hot lead from the handbars 4X4 switch and hook it to the wires going to the front coils.. I hope this helps..

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    Member Irunoldstuff's Avatar
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    Re: Polaris 4x4 not engaging

    I'll give it a try, I'm off for awile but will check it out when I'm back. That sounds like what I thought it might be.
    Thanks



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    Member Irunoldstuff's Avatar
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    Re: Polaris 4x4 not engaging

    I'm back from Maui, hoped all this snow would be gone. I had some time to look at my ATV yesterday. It was a problem with the selecter switch in the shifter. I did hook up the 4x4 circuit to another power source (grey/white wires). I hooked it with a jumper to an ignition switch powered circuit. There were two locations to use the jumper wire (4 inch - female spades). I used the upper junction this still allows use of the AWD switch. It now works great for plowing snow as I no longer need to use the override switch for reverse. As mentioned a couple of weeks ago when I first looked at this, the Neutral light is now on all the time because the switch in the shifter must have broken. I was going to disconnect the ground (brown) from the light so that the indicator wouldn't be on. Removing the ground, the 4x4 would still work but the reverse ignition retarder was on all the time, until I pressed the over ride button. I reattached the ground and just left it with the Neutral indicator on and it works. If I just attach the Reverse and Neutral indicator leads it also works, but I'll just live with the Neutral light on.
    Thanks again for all the input. Brad

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    Re: Polaris 4x4 not engaging

    I just picked up my 2003 700 Sportsmen and have similar issues, 4x4 will not engage, anyone out there got some tips/hints for me.?
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