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post #1 of 4 Old 11-17-2011, 10:19 AM Thread Starter
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POS polaris AWD

i am working on a pile of polaris shit, 96 425 magnum to be exact and the 4wd only works in reverse.. it didnt work at all when it came here but the neutral light was always on.. i took the shifter apart to get the switch working again, now the lights work the way they should and it has 4wd in reverse with the overide button in but still noting in forward.. i cant seem to find a wiring schematic on the net to do some tests and the popo dealer here is useless for info.. does anyone have any experience with the older polaris and have an idea what it is?

sons 03 Ozark, Wiseco, stg 1 cam
99 KLR650
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post #2 of 4 Old 11-17-2011, 12:13 PM
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I'm not familiar with those quads but I found threads talking about switches and it seems that there is a common problem on these quads with this happening. The first thread really deals with it. Look online for a service manual if you can unless you know the area they are talking about.

http://www.polarisatvforums.com/foru...d-problem.html

96 425 magnum 4x4 four wheel drive not engaging - ATVConnection.com ATV Enthusiast Community

Also saw this which was an interesting read concerning the reverse speed safety switch which seems to be tied into 4x4 selection but it doesn't have full diagrams.

Mechanical Forensics: Technical Essay

Interesting problem, I hope yo figure it out. I bet it's simple and you'll just have to trace some wiring and possibly mess with a relay or switch. I edited because I asked a question you had already answered.

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Last edited by JosephIV; 11-17-2011 at 12:24 PM.
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post #3 of 4 Old 11-19-2011, 12:31 PM Thread Starter
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thanks for the links, i actually suspect that switch but i dont like replacing anything untill i have tested the part and know its the problem, so a wiring diagram would be handy.. what a weird machine, it looks like it was built in someones garage with scrap metal and plastic but its the most overly complicated 4wd system ive worked on.

sons 03 Ozark, Wiseco, stg 1 cam
99 KLR650
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post #4 of 4 Old 11-19-2011, 01:36 PM
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Hope it works out for you. From what I read the 4x4 system seems pretty complex.

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