I have a 2006 Sportsmans 700 that is about a year old now. I noticed last winter that when I had the selector switch set to 2x4, it would sometimes grab like it was in 4x4. When I called the dealer, they said it was a problem they were having in cold weather. Well, now it is summer and I still have the same problem. Are any of you seeing this and if so, how did you fix it?

Thanks for any help you can provide.

Jason

 

welcome to the forum. the biggest cause of some of these happening is that the roller cage in the front housing breaks and then it wont work correctly and then stops all togther. not a cheap fix if thats what it is.

 

I would agree that it sounds like a roller cage issue. But.....it's only very expensive if you have a shop do it. I had a similiar issue w/ my 05 sp700. Diagnosed the prob thru this forum and sure enough, it was cracked up. Found I could buy replacement cage, rollers & seals for around $100 from John Deere (new & identical parts as Polaris), and did the fix myself in two nights after work. I also got a service manual from a link on this forum. If you can change your brake pads on your car, I'd say you could prob handle this fix. Has anyone ever had this fix done in a shop? I'm curious as to how much my time was worth....

 

welcome to the forum...maybe if you ask real nice you can get bigcountryusa to come over after work and fix it.......hehe.....

 

I can change brake pads and can figure out how to fix most things as long as they are not too major. What do I look for and where do I look for it at? Is this in the front hubs?

I don't suppose a case of beer would be enough to get BCUSA to come to IN for a few days would it?

Thanks for your help guys.

 

I would almost drive that far for a case of beer. Almost [img]i/expressions/face-icon-small-smile.gif[/img]

 

I don't remember how long ago it was that i read a post someone who was having the same problem you are describing said it was a bad roller cage that he found out the roller cage was made out of plastic , and he said he replaced it and the replacement was made out of the same plastic as the one that was broken ; he ask the dealer what happened to the old metal one that was in the older year model's had ! And the dealer told him that the new year model's had been redesigned and that they had been improved for the new model offered the new ADC system , and that the ADC stood for Automatic Desent Control ; was for going down very steep hill's to improve control of the quad with out having to ride the brakes or tap the throddle to engauge engine braking to slow the speed of desent down steep incline's ! A few month's later someone made a reply that the ADC was only standard on the Deluxe model's , and that to get it on other model's was optional and if you added it to another model it would cost more than the Deluxe cost's ; and that he didn't get the Deluxe package when he bought his new he had gone through 4 or 5 of the roller cage's since it was new ! He claimed that he only had a little over 400 miles on his and that he was already about to install roller cage number 6 ; when he desided this time to find a roller cage made of metal ! He said he went around to every auto parts stores and none of them had anything like it anywhere he went , untill someone told him to try an Industial supply store that they might carry something that would work as a replacement ; he said that he went to 3 or 4 stores before he found what he was looking for ! And he bought it and took it home to see if it would fit , and that it was a perfect fit and worked fine except that every now and then it would do the same thing of kicking into 4x4 mode even when the AWD wasn't switched on ; but he said he could live with it the way it was and at least he didn't have to replace the crappy plastic roller cage any more ! I've never owned a polaris before myself but a friend who live's close to me had a Sportsman 500 and he said the only thing he didnt like about it was when he rode with freind's that liked to ride in the mountain's where i like to ride he had to ride the brakes to much , and that he was on his third set of brake's while every one of his friend's were still on their original brake's ; and that he liked to ride at a place called houseton valley because the trail's there were long straight away's where you can ride fast and you hardly ever had to ride the brake's on these trail 's and it only cost $10.00 per vehicle and it was worth every penny because there were more trail's to ride on as well ! The last time i serviced the front brake's on my truck when i started to clean and repack the bearing's i noticed that the bearing case was made of some kinf of plastic , even though they were in good condition i went to the local Auto Zone Auto Parts Store and i bought a new set of inner and outer bearing's for both side's ; and i replaced them with the steel bearing's and the new race's and new seal's as well ! I bought my truck from a close freind that i used to work with before i lost my leg's in an automobile accident when we drove trucks at a local rubber and chemical company , i bought a 1987 Chevy S10 Tahoe Longbed pickup with a 2.8 liter V6 EFI in Feb. 1994 he told me when i bought it from him ; that he had the brake's and a new exhaust system with a life time garranty on the brake's and exhaust system right after he bought from a friend of his that ran a used car lot near where he lived so i don't know if the wheel bearing's were original or not ! But i do know that it had the original drive shaft u joint's were original because i took it to have the brake's redone for the second time , whitch i had to pay for the first time because the Midas muffler shop who put the life time brake's and muffler on it where the friend had them put on had shut down and moved from the town where the work was done ; and moved to another state ! But the Muffler and Brake shop that i had the brake's done checked the drive shaft , and told me it still had the original U Joint's were the type that are glugged in ; instead of the way replacement U Joint's are held in with a C or G shaped Clip's to hold the U Joint's round bearing cup's in place to keep them from coming out ! I had never seen drive shaft U Joint's that were glugged in like that before , but Clayton the manager of the shop i alway's take a vehicle to ; when i have brake's muffler's and Air Conditioner repair done and where i tell friend's to take their's to for this type of work done ! So i thought i had seen just about everything you could think of , when it come's to automotive and even small engine and quad part's made of ; but i see or hear about part's being made of it just boggles the mind of what a manufacturer will do to save money ! .....................................

 

wow willie, you love to type lol. good info though. all veiws are good in my eyes.

 

Galaxie.....the part in question is located in the front differential housing. Replacement involves removing the housing and replacing the roller cage located within it. I would say first get yourself a service manual. It will provide good pictures and directions for this fix. To summarize.....I did the following:

1. Place machine on lift and remove front wheels.
2. Remove complete driveshaft (I chose the right side to remove, and ended up leaving the left in place after I separated it from the front diff).
3. Removed front diff housing after seperating all shafts (tip: I ended up removing the cooling fan to allow the housing to slide out easier)
4. Drain fluid and unbolted the cover on the housing and replaced the roller cage & rollers. Be sure to note how it's put together for reassembly. I also replaced all seals at this time.
5. Reassemble and fill her up with the polaris demand drive fliud.

Obviously there is more to it as far as drive shaft removal and getting the housing out, but that's the basic idea. Shoot me a PM if you need the part #'s from John Deere. Check this thread out as it's where I learned of this fix with help from Mr. Adrenalator Polaris AWD Thread

 

Thanks guys. I think this will help.

I guess I will attempt to tear it down and see if I can fix it.

BCUSA- I think I got the part numbers from the other thread. It I read it right, there are two I will need or do I just need to take it apart first and see if I need both of them?