Mastering Reverse 400 Stroke With Your Polaris Atv

The 4x4 feature of the Polaris 400 2-stroke quad bike may not engage in reverse. This could be due to an electrical fault, such as dirt or corrosion on the connectors, or a faulty switch. The AWD light not coming on could also indicate an electrical issue. To troubleshoot, you can check the gear selector switch by turning on the ignition and shifting to reverse to see if the reverse lamp is illuminated. If not, you may need to check the bulb and test the related wiring. Another possible cause is a mechanical problem with the wheel hubs.

Check if the AWD light comes on

To check if the AWD light comes on, you can perform the following tests:

Firstly, turn the ignition key on and shift the transmission to reverse. If the reverse lamp is illuminated, the gear selector switch is functioning as it should. If the lamp is not lit up, check the bulb and test the gear selector switch and related wiring (as per Page 10.38 of the manual).

Next, check for battery voltage on the purple wire in the left-hand switch wire harness. If battery voltage is present, press the override button and check for voltage on any grey/white wire. If voltage is not present on the grey/white wire(s), check the override switch and related wiring.

If the entire AWD circuit tests out correctly, the next step is to inspect the wheel hubs for a mechanical problem.

Check if the reverse lamp is on

To check if your 4x4 Polaris is engaging in reverse, you should first turn the ignition key on and shift the transmission to reverse. If the reverse lamp is on, the gear selector switch is functioning properly. If the lamp is not illuminated, there may be an issue with the bulb, or there could be a problem with the gear selector switch or its wiring.

In this case, you should check the bulb and test the gear selector switch and related wiring (refer to Page 10.38 of your Polaris manual for more information). It is also recommended to check for battery voltage on the purple wire in the left-hand switch wire harness. If battery voltage is present, you can then proceed to press the override button and check for voltage on any gray/white wire. If voltage is not present on the gray/white wire(s), you may need to check the override switch and related wiring.

If the entire AWD circuit tests out to be functioning correctly, the next step would be to inspect the wheel hubs for any mechanical issues that could be causing the problem.

Check for battery voltage on the purple wire

If your 4x4 is working in the forward gears but not in reverse, there are a few steps you can take to troubleshoot the issue. First, check that the override button is being pushed, as this is necessary for AWD in reverse. Next, turn the ignition key on and shift the transmission to reverse. If the reverse lamp is illuminated, the gear selector switch is working as it should be. If the lamp is not lit, check the bulb and test the gear selector switch and related wiring (Page 10.38).

Now, to check for battery voltage on the purple wire:

With the ignition key on and the transmission in reverse, locate the left-hand switch wire harness. Look for the purple wire within this harness. You will need a voltmeter to check for battery voltage. Connect the voltmeter to the purple wire and the negative terminal of the battery. If there is battery voltage present on the purple wire, move on to the next step.

The next step is to press the override button and check for voltage on any gray/white wire. If there is no voltage present on the gray/white wire, you will need to check the override switch and related wiring. If the voltage is present on both the purple and gray/white wires, then the issue may lie with the wheel hubs, which you should inspect for any mechanical problems.

If you are not comfortable performing these tests yourself, it is recommended to consult a qualified mechanic or a Polaris dealer for further assistance.

It is also worth noting that, according to one source, the 4x4 is designed to release in reverse, and this may be due to the Hilliard clutch inside the front hubs, which locks up going forward. However, this information has not been verified, and it is always best to perform thorough checks to identify the root cause of any issues.

Press the override button and check for voltage on any grey/white wire

If you're experiencing issues with your 96 Polaris Xplorer 400 4x4 2 stroke's 4x4 not engaging in reverse, there are a few troubleshooting steps you can take. Firstly, ensure that you've pushed the override button to engage the 4x4 in reverse. If the issue persists, it's likely an electrical problem.

To further diagnose the issue, follow these steps:

• Turn the ignition key on and shift the transmission to reverse.
• Check if the reverse lamp is illuminated. If it is, the gear selector switch is functioning correctly. If not, inspect the bulb and test the gear selector switch and related wiring (refer to Page 10.38 in your manual).
• Check for battery voltage on the purple wire in the left-hand switch wire harness.
• If battery voltage is present, proceed to the next step. Press the override button and check for voltage on any grey/white wire.

This is an important step as it helps identify the source of the issue. By pressing the override button and checking for voltage on the grey/white wire, you can determine whether the problem lies with the override switch and its related wiring.

If voltage is present on the grey/white wire when the override button is pressed, the override switch and wiring are functioning correctly. In this case, the issue likely lies elsewhere in the AWD circuit or with the wheel hubs.

On the other hand, if voltage is absent on the grey/white wire, the problem is most likely with the override switch or its associated wiring. In this scenario, further inspection and testing of the override switch and wiring are necessary to pinpoint the exact cause of the issue.

By systematically following these steps and checking for voltage on the grey/white wire when pressing the override button, you can narrow down the potential causes of your 4x4 not engaging in reverse and take appropriate action to resolve the problem.

Inspect wheel hubs for a mechanical problem

If you are having trouble getting your Polaris 4x4 to engage in reverse, there are a number of steps you can take to troubleshoot the issue. Firstly, check that the override button is being pushed, as this is required for AWD in reverse. If the issue persists, perform the following tests:

• Turn on the ignition and shift the transmission to reverse. If the reverse lamp is illuminated, the gear selector switch is functioning correctly. If it is not lit, check the bulb and test the gear selector switch and related wiring.
• Check for battery voltage on the purple wire in the left-hand switch wire harness. If battery voltage is present, proceed to the next step.
• Press the override button and check for voltage on any gray/white wire. If voltage is not present, check the override switch and related wiring.

If the entire AWD circuit tests correctly and the issue persists, the next step is to inspect the wheel hubs for a mechanical problem. This may involve removing the wheel hubs for a thorough inspection and potential repair or replacement. It is recommended to consult a qualified mechanic or a Polaris specialist for further advice and assistance.

Inspecting the wheel hubs for a mechanical problem:

To inspect the wheel hubs on your Polaris 4x4, you will need to safely raise the vehicle and remove the wheels for clear access to the hubs. Ensure the vehicle is securely supported and will not roll or shift during the inspection process. Once the wheels are removed, you can begin a thorough inspection of the hub assembly, including the wheel bearings, seals, and studs. Look for any signs of damage, excessive wear, corrosion, or debris that could indicate a mechanical problem.

During your inspection, pay close attention to the following:

• Wheel bearings: Check for any signs of damage or excessive wear on the bearings themselves, as well as the races and cages. Listen for any unusual noises, such as grinding or excessive play, which could indicate bearing failure.
• Seals: Inspect the hub seals for any cracks, tears, or signs of leakage. Damaged or worn seals can lead to moisture and debris entering the hub, causing bearing failure and other issues.
• Studs: Ensure that the wheel studs are in good condition, with no signs of bending, cracking, or excessive thread wear. Also, check that the lug nuts turn smoothly and are not cross-threaded.
• Brake components: If your Polaris has drum brakes, inspect the brake shoes and drums for wear, damage, or contamination. If disc brakes are fitted, check the brake pads, rotors, and calipers for any issues.

If you identify any issues during your inspection, it is important to address them promptly to ensure the safe and reliable operation of your Polaris 4x4. Depending on the severity of the problem, you may need to replace individual components, such as bearings or seals, or in some cases, the entire hub assembly. Always refer to the Polaris service manual or seek advice from a qualified mechanic for specific repair procedures and torque specifications.

Remember to take a methodical approach during your inspection, making note of any abnormalities or potential issues. If you are unsure about any aspects of the inspection or repair process, don't hesitate to consult a Polaris specialist or a qualified mechanic with experience in ATV maintenance and repairs.

Frequently asked questions