Hello,
I have an issue with my 1998 Polaris Xplorer 300 4x4. I have been trying to figure out why it will not engage the right side front wheel when in AWD. When I engage the AWD, the front left wheel engages correctly. I just got done looking at the manual and cleaning the clutch assembly and reassembling it. Still does not engage. I checked the power wires to the hub, and that appears to be working by checking with a 12 volt tester. So I am stumped. What would make it not engage? It may be something simple, as I still am having a hard time understanding how it works. Any help is greatly appreciated! Thanks, Steve

 

A few things that still could cause problems.A weak hub coil itself can cause problems.Only test is resistance and should be around 30-35 ohms on the reading. The face of the coil sleeve has to be smooth,if worn or the inner pole on the strut casting that the coil itself fits over is worn,the armature plate may not have enough magnetic pull to slow the armature plate down so the hilliard could ramp up in the hub.A worn or warped armature plate can cause problems.Once I take a hub assy apart I replace these cheap plates. Also if the clearance between the face of coil sleeve and inner pole is not flush or is over the .001 distance allowed,it may not have enough pull. On the electrical side you may show 12 volts to the coil wire by checking the gray wire and grounding out the the other end of the test light or meter lead,but the thin ground(brown wire) may not be grounding properly itself.This was a problem on a lot of models. You can try jumping this one brown wire to a better common ground (coil mount) and see if awd operates. Or do as this guy did on a Sportsman 500 and see if this helps.