Why doesn't it engage 4-wheel drive? - Polaris 2004 Sportsman 500 H.O

cdi i doubt its bad. raise front end and try engaging . turn wheels both at same time. servo motor weak and wont shift with weight on front end . servo is magnetic shifter and engages a gear on shaft when power is applied to it. had this trouble on several of these models. try it also check lubrication level and clean grease if milky at all. water is in grease if milky dont drive it w/milk color it WILL cause damage if left in that condition.

Send issue to [email protected]. he answers for free nothn he doesnt know

2004 Sportsman 700 AWD not working..... - Polaris ATV Forum

www.polarisatvforums.com > ... > ATV Repair and Maintenance
Feb 18, 2013 - Go Back · Polaris ATV Forum > Polaris ATV Technical Discussions > ATV ... AWD wont engage. 2. The instrument / speedo works. 3. The AWD switch is ...Polaris ATV Junkie! .... four wheel drive not working polaris sportsman. Won't go into 4 wheel drive
Feb 1, 2013
4 wheel drive not working
Nov 13, 2011
2004 700, 4WD engages by itself
Oct 28, 2011
4wd is stuck on
Dec 3, 2009
More results from www.polarisatvforums.c

howdie check the vacuum lines and make sure the module is workin should be fuse for it and check for linages are engaging or the transfer case might have broken chain could be that how MAny Km,s does it have ?

On my 4 wheeler if I raise the front wheels off the ground and with the 4 wheel drive engaged you should not be able to turn the front tires two revolutions. You need to be more specific as to what you are trying to do because there are other electrical things that can be checked. Like if the 4 wheel drive will not engage. Previous test is only to see if the front end is engaged in 4 wheel drive.

The front end works off 12volts.If you have moisture in your dash your dash may not let your 4 wheel drive work and it could also not let your atv start if it doesn;t every start unplug your dash but your dash has to work to have 4 wheel drive.

Sounds like there dif is gone or drive shaft

Sounds like the switch or a relay since the front is not engaging.

it could be, polaris uses an electronically controlled lock in hub. broken wires or bad switch also.

Polaris atv manuals
Polaris ATV Repair Manuals