Recent resurrected an 03 Sportsman 500 from a nasty 400 foot fall. I have had to replace the left front rotor and hub assembly as well as the hilliard clutch. These were purchased used from 2 different locations. Now the left front tire does not engage into 4-wheel drive. My local polaris dealer tells me there is a very delicate and intricate adjusting procedure...does anyone have any experience with this? The magnet ohms within specifications and .24. Any suggestions, thoughts or ideas on how to get this front tire to engage into 4-wheel drive!!!!

 

Take it apart clean the parts make sure you got voltage then reassemble and torque to 20 lbs if it doesnt dis engage back off a tad.

 

Does your Sportsman have wheel clutches or a centralized front drive? I believe it should have a centralized unless its a 6x6 for that model year. Knowing which style of Hilliard system you have will help me walk you through how to trouble shoot the problem with your AWD.

 

Ok, forgive me but I found out that your system is the wheel clutch design for a 2003 Sportsman 500. PM me and I can help walk you through how to get it working again or tell you what parts need to be replaced in the clutch to get it working properly. Where did you buy the clutch from? Is it new or used?

 

I bought the parts used off ebay. I have power to coil