I have an 06 sportsman 500 it is stuck in for wheel drive, If the bike is on the ground it takes two people to push it. I put it on jack stands and started the bike, with the bike in N I flipped the switch to 2wd then I put the bike in low and all 4 wheels turn, and if you try to hold the front tires they keep turning, I ran it in R and then put back in low and it did the same thing. I checked the diff fluid and it is full and water free, I also checked the wire coming out of the diff and it is not frayed or cut any were. Also if the bike is turned off you can turn the front tires in reverse but not forward.

How would I check the switch or to see if the armature plate is staying magnetized.

any help would be great.. THANKS...

 

May have a broken plastic roller cage in there.............
normal WEAK point on these front ends........Caper..

 

I just had the same problem with my '06 800. I unplugged the wires going to the front dif, and it was still in 4 wheel drive so i knew it was something inside that. After doing some searching on here, and highlifters forum i found that there are some john deere parts that are a direct replacement with Polaris. When i pulled it apart i was expecting to find my plastic cage in pieces, but it was fine. Everything else looked ok too. I ordered a new armature plate, new rollers, and a seal kit and put it back together. I just finished it up last weekend, and so far so good. I'm not sure what part was wrong, but it seems to work fine now. Those 3 parts we about $55 from John Deere (a lot less than Polaris). I hope this helps a little.

 

I'll unplug it and see if it kicks out of 4x4, How were you able to get the John Deere part numbers for the diff.

 

This is just copied off of JD parts website (also listed below).

MIA10654 KIT, MINOR REPAIR ADD 13.99 USD 13.99 USD
MIA10656 PLATE, ARMATURE ADD 16.75 USD 16.75 USD
MIA10666 KIT, ROLL ADD 22.99 USD 22.99 USD
MIA10667 ROLL CAGE ASSY ADD 71.00 USD 71.00 USD


https://jdparts.deere.com/servlet/co...s.HomeUnsigned

 

Excellent post for part #s

 

Here is another link with the exploded view of the JD housing.


http://jdpc.deere.com/jdpc/servlet/c...omePageServlet

 

Another good link john deere front diff parts work

 

Thanks a lot for the help !!!!!