Ok fellas. I have a 99 or 2000 Sportsman 500 that the AWD will not engage the front hubs. I have done quit a bit of work to this machine for a friend as it was mistreated by previous owner. I did rebuild both hub clutches with OEM parts, torqued to proper value, filled with OEM fluid. Checked both hub coils for proper resistance=25 ohms, check for voltage when running in gear and awd switch to on and also the override depressed when in reverse… volts is 13.37 in all cases. Speedo does work, wiring checks good for resistance and continuity. I did try to hot wire system and still no front engage. The 99 wiring diagram shows a hub protection device/circuit which I cannot find. The 2000 diagram shows no protection device, only speedo cluster. Sticker on back of speedo says 12-7-1999. I have done many Po-Po’s (including my own) and have never ran into this…. What am i missing? Feels great to bring a good machine back to life from the dead! All replies welcome and thank you!

Ok fellas. I have a 99 or 2000 Sportsman 500 that the AWD will not engage the front hubs. I have done quit a bit of work to this machine for a friend as it was mistreated by previous owner. I did rebuild both hub clutches with OEM parts, torqued to proper value, filled with OEM fluid. Checked both hub coils for proper resistance=25 ohms, check for voltage when running in gear and awd switch to on and also the override depressed when in reverse… volts is 13.37 in all cases. Speedo does work, wiring checks good for resistance and continuity. I did try to hot wire system and still no front engage. The 99 wiring diagram shows a hub protection device/circuit which I cannot find. The 2000 diagram shows no protection device, only speedo cluster. Sticker on back of speedo says 12-7-1999. I have done many Po-Po’s (including my own) and have never ran into this…. What am i missing? Feels great to bring a good machine back to life from the dead! All replies welcome and thank you!