Polaris 4x4 not engaging

Irunoldstuff · Mar 9, 2009

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

rusty · Mar 9, 2009

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

medler · Mar 9, 2009

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

OnlyPolaris · Mar 9, 2009

probably dirty hub fluid or something wrong in the hubs.

rusty · Mar 9, 2009

replace the speedo

Irunoldstuff · Mar 12, 2009

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.

CrankShop910 · Mar 15, 2009

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..

Irunoldstuff · Mar 15, 2009

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

Irunoldstuff · Apr 5, 2009

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

TylerG · May 1, 2009

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.?

Murminator · May 2, 2009

Fuse??......

leonard · May 2, 2009

my sister had a weak battery in hers and the 4x4 wouldn't engage.
replaced and walla fixed

lacombebernats · May 3, 2009

I'm having the same problems with my 2000 400 explorer-and need parts-blew the sproket up and its now stuck in reverse-we enjoy the bike but its not strong enough for the skeg and too fast for the kids-if anyone could help with a good mechanic or parts that would be great...

cars4life · Dec 8, 2009

Irunoldstuff said:
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

So, since you now have experience with my issue, I too need help.
So I have to ride with my foot on the gear selector in order to keep the 4x4 engaged. If I let off the lever, the light AWD light turns off.
My ATV is a 1994 Sportsman 400. Non digital spedo, which means, it has nothing to do with it.
I took off the linkage and replaced the switch inside the Gear Selector and still have the same issue.
Push the selector forward and the AWD stays on, let go and just a hair of movement, the AWD light turns off. Is it the Plastic Pivot Cup inside worn?
HELP...ANYONE

mcnamash · Aug 6, 2011

I have a similar issue with the 4x4 not engaging. I am attempting to check out the speedo as suggested.
#1. Any idea how to get the headlight pod cover off? Seems stuck at the front. There are two indents in the black section from the bottom, but doesn't look like there are screws in there. ????
#2. If I replace the speedo, this may help the 4x4, but since my dash lights and low beam headlights also do not work, does it makes sense it is probably something else?

Thanks!

mcnamash · Aug 6, 2011

Where is the fuse on a 2000 Polaris Xplorer 400?

imdoo'n · Aug 6, 2011

ahem shop manual ahem

mcnamash · Aug 6, 2011

imdoo'n said:
ahem shop manual ahem

Any idea where to find one (2000 Xplorer 400)...no luck so far.

Polaris 4x4 not engaging

Irunoldstuff

New member

rusty

GBCA Member

medler

I love guns

OnlyPolaris

Active VIP Member

rusty

GBCA Member

Irunoldstuff

New member

CrankShop910

Active VIP Member

Irunoldstuff

New member

Irunoldstuff

New member

TylerG

Super Mod Geek

Murminator

Timber King

leonard

Active VIP Member

lacombebernats

New member

cars4life

New member

mcnamash

Member

mcnamash

Member

imdoo'n

Active VIP Member

mcnamash

Member

Similar threads