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Does any body know how to by pass the on demand 4 wheel drive on a 2004 polaris sportsman 500 so that when i put the switch in the 4 wheel drive position it is in 4 wheel drive all the time and out of 4wheel when i turn the switch off i saw a kit on ebay but the seller said it was so simple that they would not show a picture of the kit
I dont have an answer for you, but i dont think you would want to do that. The awd system on the sportsmans has both a locked front and rear differential, as well as a lock between the front and rear drive systems (like a jeep wrangler, except with front and rear lockers). If you engaged awd continuously, there would be no differential action between the different tires, making steering effectively IMPOSSIBLE. If you do a search, this has been brought up before.
If you know all this anyway, the hilliard clutches in the front hubs are not designed to be "engaged" and locked on. they only engage when the axle begins to turn faster than the wheel. So there is no electrical solution to this proble; a mechanical one is needed.
To experience the full locked feeling, put the sportsman in awd and pushing reverse override, spin the tires in reverse, and stop when the front wheels kick in. shift to froward without releasing the brake. Occaisionally, the hubs will wedge in place, and you will have continuous awd. This can be used on a hill for 4 wheel engine braking, but as i said, steering becomes very difficult.