i have a 1998 500scrambler 4x4, after going through deep mud and water my 4 wheel drive started acting up REAL bad, pulling really hard. i got it home took hubs apart and cleaned everything and filled back up with polaris hub fluid, everything looks mint in there i put in new armature plates last month. after cleaning it still pulls not as bad but still really noticable. i even tryed unhooking the wires going to the hubs and still the same. can anyone ofter any help on this???????

 

Is the hub staying locked? or is something else dragging (brake, wheel bearing, etc.)

 

no brakes hooked up, all bearings are good, like i said everything looks like new, and even with the hub wires unhooked it still sticks

 

Lift up the front and turn the wheels, do the axles turn?

 

did you hit anything maybe alighnment isue

 

you would think it would be either a bad bearing, or that side awd sticking is usually the cause.like mentioned, try jacking it up and roll that side to see whats happening??

 

Read this link and you will be a AWD expert ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

here is one thing they mention. as well as a Pole clearance of 0-0.001" . Also you castle nut can,t be tighter then 12'- lbs.

How to measure pole clearance from above link.

 

Change the hub fluid.

 

Axle nut not torqued correctly or residual magnetism would be first.

Are all of your tire pressure set correctly? That machine had 1 inch larger front tires to keep the AWD clutch overdriven. If the fronts are soft or or rears overinflated you can get closer to 1:1 speed ratio. Well with another sip of coffee and a few more braincells working.... it wouldn't matter with AWD off.