Polaris AWD not engaging!!!

[2012DXT]

I have a 2001 Polaris Sportsman 400 I just recently got running. Been sitting up for about five years after being broken down and not having the time or money to fix it. I've get her running tip-top, but my AWD won't engage.. Are any of y'all familiar with these bikes and this particular problem?

Thanks, Dustin

[2012DXT]

And yes, I'm aware this isn't an ATV forum, I just trust everybody on the GS more than other sites!

[focushunter]

Does the guage work?

[focushunter]

There is alot of things it could be!!! If the guage isnt working right it will cut it off. Dont remember on the 400 if they have a spage cage but that could have a crack in it.

[2012DXT]

The guage doesn't work, it used to be moms and she said the guage had been out for a while and the AWD still worked..

[2012DXT]

Before water and mud got in the casing

[bowhuntntxn]

If it has been sitting for a long time, it might be seized up, especially if it has water and mud in it. Only real way to tell is to crack open the case and see how bad the corrosion/gunk is in there.

[2012DXT]

I already have it running, sand blasted the flywheel, replaced the stator, starter, bendix drive, battery, petcock, all the fuel lines, flushed the tank, changed all the fluids, and rebuilt the carb. Runs excellent, just won't engage when I flip the switch for my AWD

[SB09]

The guage doesn't work, it used to be moms and she said the guage had been out for a while and the AWD still worked..

Is she 100% sure of that? Every other case I've seen if the gauge is out, the 4x4 isn't going to work unless a bypass switch is put in.

[2012DXT]

She swears on it, but I planned on bypassing it tonight after school, just hoping somebody might have a better solution..

[SB09]

She swears on it, but I planned on bypassing it tonight after school, just hoping somebody might have a better solution..

That's what I was going to recommend. Try out the bypass and see if it works.

If it doesn't you're looking to see if you have power to the hub wires on the left side. If you do have power to there then you need to start checking magnets and armature plate and follow that down the line. I honestly think the gauge is the problem just judging by how common it is with these ATV's.

[2012DXT]

There are two connectors that run down to each hub that go into the main harness and run to the power source. Both connectors measured around .5V, that was with the switch on, I'll check it at the hubs and see what I'm getting. I'm not even sure what voltage I need, seems low.

[2012DXT]

The connectors have two prongs, each measured over .5V, so together, there is a little over 1V to each hub. Just don't seem like enough. I'll check it at the hub tonight.

[2012DXT]

Bump!