My 2005 sportsman 800 has only 275 miles on it . I was riding in snow and ice. I had 4wd disengaed , I hit the gas pretty hard (in forward) and found out that 4wd was not fully disengaged.I felt a prtetty hard bang from the front differential.I kept riding in 2 and 4wd with no problem. I returned home and found out 4wd (in reverse only) does not engage. The override button seems to be working. With the quad off the ground and the rear wheels spinning in reverse I get a electrical hum in the front differential but no engagement Anyone have this problem ? Any suggestions?

 

is the awd coming up when you push the override in reverse? if so then chances are you took out the roller cage in the front end.

 

The awd does come on.I heard John Deer has a roller kit and roller cage that will fit .I heard it is much cheaper than polaris and possibly stronger .Did you hear anything about this?Thanks for the responce.

 

http://highlifter.com/forum/jo...work/m_1942879/tm.htm


This has all the info you'll need for fixing a broken cage with John deere parts

 

Thanks .Is the 700 & 800 front differential the same?

 

The diff should be the same from the 450s to the 800s

 

Thanks.I ordered the parts.Any tips on installing?

 

Disconnect all electrical points and apply di electric grease to them if this does not help you have to make sure your getting good electrical current to the hub. Polaris uses a Schnider Sprocket design that been in use since wwII. The design inherently does not work well in reverse going down hill. Try the quick fix and if it doesn't work I'll get you the ohm you need to read on the black line swithching the hub.

 

this bike doesnt have any hubs. the awd is strickly in the front end now on thr new ones.

 

I might have the pages from the service manual that I could take some pictures and email them to you.