I just put in a new hub coil on my 2000 Sportsman 500. I had 3 wheel drive before I put the new coil on the wheel that would not spin. It still won't spin. I have oil in the hub, the armature plate looked fine not wurped. The coil came with a new connector so I don't think that would be the issue. I guess I need to make sure it is getting power? Any ideas?

 

New coil sleeve along with the coil? Is the coil sleeve flush or about .001 clearance from strut inner casting? Also 12 pounds torque on driveshaft nut? Every thing has to be just right for awd to work properly. Did you check to see if armature plate held tight against coil with switch on and easy to remove with power off?

 

I had the same problem on my machine (2000 sp500). The problem was a wire was grounding out against the frame and not sending power to the AWD on one side. The wire was repalced and I had not had any problems since.

Thanks,

Jim

 

Here is a good link with pics to tell you if you put it all together right. ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

 

I believe I am real close to the .001 clearance. I have the thinkness of a little more the thickness of a penny. I think I will get a new armature plate, mine did not looked warped but if did have some shiney marking on it. I do not have a torque wrench put I assume 12 lbs of pressure on the castle nut is not much. Thanks for the help guys.