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('99 & Early 2000 Sportsman 335, '99 Xplorer 300)
All Wheel Drive Activation In Reverse: For AWD in reverse gear, the override button must be pushed in addition
to selecting "All Wheel Drive". Power is delivered through the transmission switch, the override button, the AWD
button, and then to the front wheel coils.
All Wheel Drive (AWD) Testing
The All Wheel Drive (AWD) system is activated when battery voltage is supplied to the front wheel coils. Always
check battery voltage when an AWD problem is encountered. Charge battery and check charging system if nec-
essary. If only one wheel hub does not engage, test wheel coil resistance and inspect wheel coil wires for damage.
Check for a mechanical problem if resistance measurements are within specifications.
1. Remove cover(s) as required to gain access to terminal board.
2. Turn ignition key on and shift transmission to a forward gear.
3. Select AWD with AWD button.
4. Check for battery voltage on gray terminal at terminal board or harness connector. NOTE: If power is present
and bulb is good, All Wheel Drive lamp will be lit.
*If voltage is present:
SDisconnect Gray and Brown wheel coil wires and test resistance across the small wheel coil
wires. There should be 25-30Ω of resistance.
STest Gray wire to ground on strut casting. It should be an open circuit (∞). Move wheel coil
wiring harness while performing the tests to check for an intermittent open or short.
AWD Wheel Coil Resistance
Gray to Brown
(No continuity to ground on strut casting)
SRepair wiring harness or replace wheel coil if necessary.
*If no voltage is present on the Gray terminal check the AWD switch and transmission switch. (If voltage is
present on the Gray/White terminal transmission switch is functioning properly.) Refer to AWD and
Transmission Switch Testing this section.
No AWD in Reverse
If AWD functions properly in forward but not in reverse, perform the following tests:
NOTE: Override button must be pushed for AWD in reverse.
1. Turn ignition key on and shift transmission to reverse.
2. If reverse lamp is on, the gear selector switch is functioning properly. If reverse lamp is off (not illuminated),
check the bulb and test gear selector switch and related wiring (Page 10.38).
3. Check for battery voltage on Purple wire in left hand switch wire harness.
*If battery voltage is present:
4. Press the override button and check for voltage on any Gray/White wire.
SCheck override switch and related wiring if voltage is not present on Gray/White wire(s).
If the entire AWD circuit tests correctly, inspect the wheel hubs for a mechanical problem.
No All Wheel Drive (AWD) on Shaft Drive Models Equipped With Hub Safety Module
(Refer to specific wiring diagram for application).
1. Perform circuit tests above. If the tests are within specifications, proceed with the following module by-pass test.
2. Inspect the Red/White and Brown/White wires leading from hub safety module to the terminal board.
Connections must be clean, tight, and properly color-matched to the terminals.
3. Disconnect Brown/White wheel coil wires from terminal board and connect to Brown (ground) terminals. If All
Wheel Drive functions properly, replace wires on proper terminals and proceed with next step.
4. Disconnect the Yellow/Red wire from the Hub Safety module.
5. Test AC voltage input at the Yellow/Red wire (on alternator side). Voltage should be a minimum 5 AC volts at
idle. Refer to charging system testing if voltage is below 5 AC volts.
6. If voltage is present on the Yellow/Red wire and the system does not function correctly, replace the module.
Polaris Sales Inc.
25-30Ω
10.41
ELECTRICAL
All Wheel Drive System
99/00 ATV Update
12/99
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Troubleshooting
