I have a 97 Xplorer 500 that I have read what everyone else has done and I have cleaned everything. Replaced the hub springs, spacer plates. Does anyone have any ideas. The magnets work. I got this bike used and was told everything worked. I have a new battery also. I would appreciate any help.

 

tHE CORRECT TORQUE ON THE WHEEL HUB IS CRUCIAL. ARE THE COIL SLEEVES PERFECTLY IN LINE?

 

Yes they are I am almost wondering if someone has put the wrong hubs on it.

 

they don't have any different hubs. They are basicly all the same. It is a very simple system that works great but all the ducks have to be in a row. Does it have an armature plate in it? Are the tabs on the plate set in the clutch? Does the Neutral reverse light work correctly in the right gears? Does the AWD light come on when you push in the button?

 

I am not sure what the torque is set at on the nut. I do know that the plates are new. I cannot get either side to lockin. If you put it in 4wd the light comes on the plates stick to the ameture. In rev. the awd light does not come on util u push the override button. The plate is set in the clutch. I had a 96 explorer and had pulled it all apart and put it back together and it all worked fine. If the magnets are not strong enough would that cause it not to engage? I bought this bike used and the 4wd never worked. So I am not sure what the issue is. I had seen where there were different part numbers for the hubs. I was wondering could they be worn out on the inside if someone did not keep enough fluid in it. It does not have any heat marks or anything.

 

You can take the hub off and with the key on (not running and put it back together without the hub on it) and turn the back wheels and see what is happening. if the armature is slipping then you may need new plates. They have to be pefectly flat. Any dishing to them and it will not make enough contact to hold. When the magnets are on the plates should be very hard to pull off. (if you even can)