I have 2002 Polaris 325 4x4. I am having problem with left front no 4 wheel. I took It apart,Electro coil was worn spots on It. So I put on a new coil & new seal sleeve. The armature will stick to the coil sleeve when i flip the switch to AWD. I put It back togather and still no 4 wheel, I took apart the Hilliard Clutch clean all the rollers and the cage no burrs everthing looks great. still no 4 wheel. Please give me something to go on. It Is driving me nuts. Thanks
Cbhunting

 

welocme to the forum. stupid question, but are you using the correct hub fluid when filling and not overfilling? just a thought as this can effect how it works.

 

may have to move the seal sleeve in or out a little, most of the time they need to go on farther, do you have a book? it tells you how to measure to get it right, when its right you really have to work to get the armature plate off the magnet, did you replace the armature plate? they get warped ,bent, magnetized, need to be replaced

 

Read this ,it has good info.ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

 

,Yes I have the service manual. I checked the gap around the sleeve It seem to be OK, & all the tabs look good. When I put the new seal sleeve on I put It on pretty
close to the magnet. Do you think It could be the armature plate .
I use Polaris hub oil & Fill to 3 or 9 o clock
Thanks
Chuck

 

Maybe a broken wire somewhere and the hub is not getting its current.

 

2002 polaris 325 magnum
right side Is OK. Left side very little magnetic on the armature. I switched the armature plate with the outer side It didnt help.I do have 12volt at the plug.
But the hub seal sleeve get pretty warm to the touch. I replaced the coil because the old one looked like it was melted rubber / with some bare wires being exposed. So I have had this problem for some time just didnt know It.
Could It be a ground or a hot wire some were. Please give something to go on.
Thanks
Cbhunting

 

sounds like you did everything right,try checking the connections where you plug the coil in and work your way back to the switch. in some cases you can trade connectors from side to side and then you might find out what the problem is.

 

Thanks guys, I will try some of your remidies