The 4 wheel drive is sometimes sticking in the engaged position when I switch back to 2 wheel drive. Putting it in reverse and backing up 10 ft or so usually disengages the 4 wheel drive. Any idea what the problem is and how to fix it?

 

Welcome to the forum. Does it do it a lot? If it does there's a problem. My older 500s would only do that if I had it in 4x4 and reverse and used the rev over-ride. If it only does it then, it's not a problem.

Frank

 

It does it whether or not I'm going forward or reverse while in 4 wheel drive. However, it doesn't do it every time, maybe 50% of the time.

 

Could be possible roll cage damage/wear in front gearcase locking in awd?

 

I too have this problem - a mint shape 05 with only 70miles on it. I changed the front diff fluid with no effect and am hoping the cage is not broken already! Anyone have anything to add or a similar experience?

Thanks.

 

Ahhh, the joys of Hilliard Clutch front ends. it's a good system when it works that's for sure, but when something goes wrong.... oh boy!!!

I have a few friends who are certified small motor mechanics and VERY knowledgable on ATVs. One buddy's Popo is a certified "Honda" (3 wheeler) ahaha. He has rebuilt the AWD system on that hub twice and done everything he can think of, to no avail.

My advice, take it to a dealer! Suck it up and pay for it. That way, if it doesn't fix the issue, you can go to them and get them to fix again on their wallet this time. I think in the long run, it will save you money and definately time!!

If my AWD system ever acts up, I know I will be taking it in. I would rebuild the engine, but not mess with the AWD system.

Again, just my opinion.

 

Start by changing the front end oil with the Polaris brand and type. If that dont work it could be mechanical. start with the easiest first.

 

Thanks for the replies guys. However, you should know that this is an 05 which has the central hilliard clutch, not the two separate hubs on either side - my 01 was like this and I became much too familiar with this system. The central hilliard I haven't messed with which was one of the reasons I bought a newer machine! And now to have it fail as well...! Sigh. Not very impressed, actually. I love these bikes but I must say that I am very dissappointed with how this is working out.

Also, 02magnum500, I did change the oil in the front diff first thing, which you must have missed in my post. ( : No difference there.

Any more suggestions? I am thinking (judging from the posts I've read) that it is either a broken cage (but the AWD does work, you just have to reverse before it disengages) or a permanently magnetized amarture plate. If the central hilliards do indeed have an amature plate that is... Any help anyone?

-Brett

Ps. This unit sat in storage for a couple of years so I am thinking it has had time to gum up or get magnetized. Not to jump to conclusions....