Polaris Sportsman 400 4×4

Hello all. I have a 1994 Sportsman 400 4×4 that I would like to rig the 4×4 to a toggle switch so I can have 4×4 when I want it. The On-Demand doesn’t work faithfully. I’ve gone thru the front hubs and cleaned them up, put new seals in and check that the stater plate is flat and has the correct clearance. I’ve found the wires coming up from the hubs to where they plug into the fuse block. With the quad in forward and the AWD botton on, I have 12v at the fuse block. I was wondering if I could run 12v from the fuse block thru a toggle switch and turn the hubs on and off that way. I would use a 12v source on the fuse block that was on when the key is on. I’m not sure how the quad knows when to engage the front hubs. I know the owners manual says it’s when the rear wheels are turning faster then the front. I also know there is a speed sensor on the quad, but I don’t know if this is somehow tied into the On-Demand stuff or not. I know this is going to set off all the anti-Polaris guys. I only use the quad for ice fishing, it runs grant, starts everytime. I just want the 4×4 to work. I’m a do-it-yourself guy. Can’t see spending money to take it to the dealer for something I can fix. Thanks in advance.

I have a ’95’ and when I put it in 4×4 it locks in and pulls along with the rears. I also have a ’92’ that I don’t ride much but it does the same, front pulls along with the rears, I’m not really familiar with the ‘on demand”, it’s either in 4 wd or it’s not. Sometimes when I take out of 4 wd I have an issue with the front unlocking and they will pull real hard to one side or the other, then I have to go in reverse to unlock them. Now in reverse, sometimes I have to push the override button to lock in the fronts to go backwards in 4 wd. I haven’t ridden my a lot lately but I’m quite sure memory serves me right.

I would sale it and get a newer machine. Get as much money out of it as you can. It will not be much but, worth it. I have a 07 Sportsman 700 and have no problems with the 4×4 or any other part of the machine and love it. Friends of mine that have older ones are selling theirs to get newer ones. They are tired of the small repairs that add up in the long run. It is sure nice to go any where I want to and not worry about anything, when others can’t because something is broken or it will not work right. Part with the machine and get a new one, their is a big difference. Good Luck

I agree with the newer machine. The problem is I just don’t use it enough to warrant spending the money. I bought this one from a friend who rebuilt the engine so I know that’s good for a while. So far I’ve got $80 in the machine for new seals in the front hubs and a little sweat equity. There’s always the issue with the little women, I know I don’t have enough pts built up for a different quad . I’ve got a couple of ideas on how to lock the hubs in all the time, might just do that.

First off is it a Quad or a Sportsman two totally differnet machines. If it is the sportsman when the 4 wheeler is put in gear there is a switch in the shift box that allows the 4 wheel drive to kick in. In reverse you have to use the button on the handlbar for 4 wheel overide. The shifter wears and will not engage the 4 wheel drive switch properly ie sometimes it works sometines it dosen`t. This is due to wear of the shift rail and the lower shifter. What i did to mine was pull the shifter box apart and built up the tab on the shifter with a small weld and filed it back down. Works 100% of the time now. An easy job if you pull it apart just becareful there is a strong spring holding the shifter down into the rail.

POINTS!!!!!!!!!! I must be the few husbands that got lucky. My wife is the deciding factor (YA RIGHT). She is the one that found my sportsman. I held off for a couple of months then she brought it up again after we went wheeling with some friends. I called the dealer on a Wednesday and picked it up on the following Monday. We have never regretted since.

I understand if finances are an issue, do what you can. You need to ride more go around the neighborhood do something. JUST DO IT. GOOD LUCK..

I have 1994 sportman 400, 4 wheel drive doesn’t work in reverse. any ideas?