So far I have changed all 14 of the roller bearings,front bearings, both spined shafts the plastic roller rides on, the bearing in between, and seals in the demand drive. The machine is basically enguaging the 4x4 once the drive shaft spins fast. I have tried to unplug all the magnet wire and the switch on the handle bars and no change. I tested this with the machine on the jack. The switch will enguage the 4wd properly. Does anybody have any ideas???

 

Replace the prop shaft and I bet will fix it. Yo either have a bent propshaft or front axle. The vibration no matter how little kinda makes a magnetic field and can cause engagement.

 

I could try that. I have another 800, but B-4 I replaced all the parts it the diff I spun the diff with a screwdriver and it was still locking in on its own. So I don't think that is it. :-( If the machine is jacked up so the axles are not spinning and the magnet is unplugged I thought it would me mechanical also. Any other ideas?

 

Maybe it became permanently magnetized. See if a screwdriver sticks to it with the wire unplugged.

 

I have had the cages not fit correct before. They would be 2 big and would not be able to turn past the lobes in the diff without getting stuck. I've sanded the cage evenly until it would barely slip by the lobes and it worked fine. If it is doing it on the bench then it won't be the propshaft. This was on brand new cages, not the old one I took out. As far as it spinning with High speeds, it could still be the propshaft. Was it engaging on the bench before you replaced parts?

 

You're armature plate is probably magnatized.It stays attracted to the coil keeping the cage engaged.

 

I have done this several times and have even replaced the hole diffieretial and it still does it. Change the oil and let her eat. If you want to spin tires from time to time I would recomend replaceing the roll pin on the shaft with a quick release so that you can take the shaft out easily.

 

Ncrider forks- It was still locking in on the bench b-4 I replaced the parts. I did not replace the Plastic carriage. I did not try it on the bench b-4 I installed it. Probably should have though! Not fixing it seems hard on the diff. It is like doing a neutral safety dropp on the diff!!

 

You ARE using the correct fluid for the diff aren't you?. Polaris has a new diff fluid for their machines. I believe its called Premium Demand Drive LT. Its for both ADC and Non ADC equipped quads. If not sure what you have, call Polaris and ask what you need.

Make sure the dealer isn't selling you the wrong type diff fluid.

 

I thought that might be the problem, so I bought some lt fluid and changed it out. Unless there is still some old oil in there. I could try changing it again. I did put gear oil in it when I filled it full of water @ creekbottom. But I have changed it since then.