My friend just got a 2001 Sportsman and it keeps kicking out of AWD. Is this a common problem with these? I know my 2006 I had to replace the plastic cage and armature plate to fix it, but that was because it kept kicking in AWD not out. Does anybody have any ideas on what it might be, or have a manual for it? Thanks!!

 

try cleaning the awd switch with electric cleaner , then check all connections from switch to hubs, under the front rack and plastic you will find the wires going to the hubs, think there red and gray , check them out going down the struts and make sure there not pinched or rubbed in two

 

if the awd indercator is still on then maybe see if there is power down to the hubs. change fluid if he hasn't already w/ the correct hub fluid. he doesn't have the same style hillard system on the older bikes where they have hubs(no plastic roller cage).

 

if its a 2001 sportman 500 it does have hubs

 

I knew about the different hubs...I used to have a 96 scrambler 400 as well. I am just not as familiar with that style as i am the newer ones. Thanks for all of the help though, i will just have him start going through all of the wires and see if that gets him anywhere. It also has issues starting ones it is warm. Any ideas on that? Anybody have a pdf manual, or know of where to get one also. Thanks again!!

 

part shark .com

 

thats what i was trying to say as the older models like the 01'(like my old 02 i had) does have the hubs and not the roller cage style.

 

Next time it happens have him hold the shifter into gear to engage better. I spoke to someone recently that had the same problem and by chance they held the shifter and it started engaging all the time. I pointed him in the linkage adjustment direction, but he hasn't actually done it yet.

 

Not to change the subject, but I have had the best luck out of my 2001 500 that I could ever imagine. Its like a tank...it hasnt been babied either. Ive had a 2003 500 and still have my 2004 700 and they have had their issues, but the 2001 500 has taken a beating....anyone else?

 

The older ones have Hillary's with roller cages, it just that they have one in "each" hub and there made of metal, not a single Hillary in the front diff with a single plastic roller cage.

Here is great info on them ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

Heres the what one of the hub roller cages look like. Not only are they stronger there are two of them taking up the stain, not just one made of plastic.