I had the age old only one front wheel engaging! I just bought my'03 Scrambler 500HO from my friend, knowing of this problem, I decided to check it over myself... All the electrical looked and Spec.'d ok. So there I was stumped !!! Until I took a closer look @ the manual. Then a close inspection of the Hilliard Clutch and.....I found that the rollers required a good bit of force to move outward and inward.They were hanging up in the slots! Well, I decided to file the slots a little by hand with a file, just enough so that the rollers slid in and out without resistance (ecept for the spring tension). I put it all back together filled the hub with fluid and went to the local mud spot for a test. It worked perfectly!!!!!!!! I just thought this little tid bit might help a few people out. The dealer told my friend that it was gonna cost $1,000.00 to fix the problem and then they didin't put the hub back together properly!!!!

 

when you need to check out the engagement of the 4x4 in your garage. just lift the whole atv and put it on a milk crate. turn it on, put in gear with awd switch engaged. and see it work. see it disengage also................!!!!!!!!!!!!!!!!!!!!!!!!...... ............great job on your part too.............................!!!!!!!!!!!!!!!!!! !!!!!!!!

 

nothing wrong w/ saving money. sounds like the manual was worth having.

 

10/4..............!.....the Holy Manual...........!!!!!!!!!!!!!!!!!!!