ok so i have 04.5 sportsman 700 efi and last time i took it out didnt have awd ,so i checked to make sure i have 12 volts going to it and i do. i started tearing down frontend to remove the diff and started having trouble getting axles out so i left it alone for another day and yesterday i get home to work on it and thought id jus check to see if awd was working so i cranked it up with it on jackstands and now the frontend turns without the awd switch even being on !im baffled cuz first it wouldnt do nothing and now it engages with switch off . i, wondering if the armature is stuck or something ? should i go ahead and pull the front diff out and see whats going on inside ?

 

With the load off the front end if the armature plate has magnetized possible for it to engage the roller cage even out of awd mode. But back on the ground the cage may be cracked to where it won't engage in awd with weight back on the front diff. I'd still pull it down. Replace the plastic roller cage with an aluminum aftermarket one,plus I'd always replace the armature plate too as it wears right along with the roller cage.http://www.ebay.com/itm/Polaris-Sportsman-700-Hardened-Aluminum-Sprague-Cage-Roller-Carrier-ARC-P-022-/201046762123?pt=Motors_ATV_Parts_Accessories&hash=item2ecf52228b&vxp=mtr

 

yea but when i first put it on jackstands and cranked it up ,the awd wouldnt kick in and the next day it started working and it now itwont disengage even with the harness unpluged. i read where ppl using john deer parts on these things and wondering if its the aluminum cage theyre buying

 

It won't disengage usually because the armature plate is magnetized and "tricks" the system. Same thing that can happen on the hub activated systems if the armature plate magnetizes. One side or the other can lock making steering hard. You have to back up which usually frees the system up. Some used John Deere parts,but the cage is just a harder plastic from what I understand and takes a while to break in properly. With all the problems of plastic roller cages and armature plates,I'd do it right and replace both and be done with it.

 

so you think i should replace the cage and the armature plate and see what happens

 

do you have a link for ebay to find the plate like you did the cage

 

My best guess on this.Polaris even offers "performance" roll cages as an option on the parts break down which are just aluminum cages! Aluminum cages are far less prone to have problems along with replacing the armature plate. I'd hate to have to go back into something twice.

 

yea i was thinking the same thing , now if i can find the armature plate for this thing ebay!if you got a a link it would help !!!

 

Here's the list of armature plates that should include your model.

Usage : 3234160

Year Product Model Assembly
SERIES 11 PPS UTV 2X4/4X4/6X6 FRONT HOUSING - C11RD50AA/AB/C11RF50AA
2008 RGR RANGER 6X6 700 EFI DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RF68AD/AF/AZ
2008 RGR RANGER 4X4 500 EFI DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RH50AF/AR/AT
2008 RGR RANGER 4X4 700 EFI/XP ALL OPTIONS DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RH68 ALL OPTIONS
2007 RGR RANGER 500 2X4/4X4 GEARCASE, FRONT - R07RB50AA/RH50AA
2007 RGR RANGER 700 EFI 6X6 GEARCASE, FRONT - R07RF68AD/AF
2007 RGR RANGER 500 EFI 4X4 GEARCASE, FRONT - R07RH50AF/AR/AT
2007 RGR RANGER 4X4 700 EFI/LE GEARCASE, FRONT - R07RH68AD/AG/AH/AK/AL/AO/AP/AW
2006 ATV MAGNUM 330 4X4 HOUSING, FRONT (DEMAND DRIVE) - A06CD32AA/AB/AC
2006 ATV SPORTSMAN 450 HOUSING, FRONT (DEMAND DRIVE) - A06MH46 ALL OPTIONS
2006 ATV SPORTSMAN 500 HO HOUSING, FRONT (DEMAND DRIVE) - A06MH50AA/AB/AD/AF
2006 ATV SPORTSMAN 500 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH50AQ/AX/AY/AZ/AL/AT
2006 ATV SPORTSMAN 500 HO INTL HOUSING, FRONT (DEMAND DRIVE) - A06MH50FB
2006 ATV SPORTSMAN 500 EFI INTL HOUSING, FRONT (DEMAND DRIVE) - A06MH50FC
2006 ATV SPORTSMAN 700 HOUSING, FRONT (DEMAND DRIVE) - A06MH68AA/AD/AF
2006 ATV SPORTSMAN 700 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH68AQ/AT/AX/AY/AZ
2006 ATV SPORTSMAN 800 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH76AL/AQ/AT/AX/AY/AZ
2006 RGR RANGER 500 2X4/4X4 HOUSING, FRONT (4X4) - R06RD50AA
2006 RGR RANGER 500 4X4 EFI HOUSING, FRONT - R06RD50AB/AC
2006 RGR RANGER XP 4x4 700 HOUSING, FRONT - R06RD68AA/AB/AC/AD/AE/AF
2006 RGR RANGER 6x6 EFI 700 HOUSING, FRONT - R06RF68AA
2005 ATV MAGNUM 330 4X4 FRONT HOUSING - A05CD32AA/AB/AC
2005 ATV ATP 330 4X4 FRONT HOUSING - A05JD32AA
2005 ATV ATP 330 4X4 QUAD FRONT HOUSING - A05JD32EA
2005 ATV ATP 500 4X4 FRONT HOUSING - A05JD50AA/AB/AC
2005 ATV SPORTSMAN 400 FRONT HOUSING - A05MH42AB/AG/AH
2005 ATV SPORTSMAN 500 HO/INTL FRONT HOUSING - A05MH50AB/AC/AG/AH/AL/AT/FB
2005 ATV SPORTSMAN 600 FRONT HOUSING - A05MH59AK/AN
2005 ATV SPORTSMAN 700 EFI FRONT HOUSING - A05MH68AC/AS/AT/AU/AW
2005 ATV SPORTSMAN 700 FRONT HOUSING - A05MH68AK/AN/AD
2005 ATV SPORTSMAN 800 EFI FRONT HOUSING - A05MH76AC/AT/AU/AW
2005 ATV SPORTSMAN MV7 HOUSING, FRONT - A05MH68AP
2005 MIL SPORTSMAN MV 7 GEARCASE, FRONT - A05MH68MB
2005 RGR RANGER 2X4,4X4,6X6 FRONT HOUSING (4X4)(6X6) - R05RD50AA/AB/AC/AD/RF50AA/AB
2005 RGR RANGER XP HOUSING, FRONT - R05RD68AA/AB
2004 ATV MAGNUM 330 4X4 FRONT HOUSING - A04CD32AA/AB/AC
2004 ATV A04CH42AQ SPORTSMAN 400 FRONT HOUSING - A04CH42AQ/AR/AS/AT/AV
2004 ATV A04CH50AQ SPORTSMAN 500 FRONT HOUSING - A04CH50AO/AQ/AR/AS/AT/AV/AW/AX
2004 ATV A04CH59AK SPORTSMAN 600 FRONT HOUSING - A04CH59AK/AL/AN/AQ/AW
2004 ATV A04CH68AK SPORTSMAN 700 FRONT HOUSING - A04CH68AK/AL/AN/AO
2004 ATV A04CH68AU/CU SPORTSMAN 700 FRONT HOUSING - A04CH68AP/AQ/AU/CU
2004 ATV ATP 330 4X4 FRONT HOUSING - A04JD32AA
2004 ATV A04JD50AA ATP 500 4X4 FRONT HOUSING - A04JD50AA/AB/CA
2004 RGR RANGER 2X4,4X4,6X6 FRONT HOUSING (4X4) (6X6) - A04RD50AA/AB/AC/A04RF50AA

But these show to have been updated to this part #3234101. Make sure your armature plate looks like this one before you order this part #.
http://www.ebay.com/itm/NEW-OEM-POLARIS-ARMATURE-PLATE-RANGER-LSV-MAGNUM-SPORTSMAN-3234101-/271607901697?pt=Motors_ATV_Parts_Accessories&hash=item3f3d17ae01&vxp=mtr
Plus here's a NOS #3234160 plate as it does show to be different. The 2004.5 would use one or the other or could possibly use either one.. That's why I hated mid year models.. http://www.ebay.com/itm/POLARIS-ARMATURE-PLATE-3234160-/271634270570?pt=Motors_ATV_Parts_Accessories&hash=item3f3eaa096a&vxp=mtr

 

thanks so much for all your help ! ill post results or more questions