G'Day Gents

I was hoping for some help in my newest problem. I have a 2010 Sportsman 400 HO (hawkeye) with 26" tires. The last two times I was out my AWD has been acting up. We have been doing alot of ice riding and it is quite evident. After the first trip I checked and have the correct amount of Ohms at the front gearcase. I checked and ensured my battery and charging system is good. I am getting well over the 11.8 volts at the front gearcase. I figured I had it figured out as it was working again. Then went out the second time and was acting up again. To test it on the trail I would plant the front at the base of a large tree and give it throttle. It would kick in eventually but it took a lot of throttle and then it would violently "SNAP" in to 4x4 and would work normally until it disengaged and would have to rev the S&*% out of it to SNAP back on. Always violent. Figured it was just frozen.

I let it thaw out in the garage over night and most of the day then went out this evening to check it out. Put it on the hoist and nothing at first then revved the S&^% out of it and "SNAP" working again. took it out for a rip and no change every time i needed it i would have to excessively rev it.

What does this sounds like? I am baffled

Some things I noticed:
- The prop shaft from he tranny to the front gearcase doesn't turn very straight.
- After the load "SNAP" while it was on the hoist I rolled each CV Axle and they turned independently (I remember them always normally turning in tandem)
- When I was diagnosing it after the first ride I drained the fluid and there was quite a bit of shavings in there (prob drain and inspect tomorrow)
- I know I need a new belt but don't think that would cause this (another problem why am I burning through belts?)

Thoughts on fixes:
- through my searching i found that the 500s had a grounding issue with the speedo. Would this cause my problem? there is nothing if the AWD kicked in with excessive throttling.
- If it is the armature and roll cage do they even make a metal one for my ride?

I will take a video tomorrow and upload it.

any advice or expertise in the matter will be greatly appreciated.

 

Sounds like the same old cracked plastic roller cage in the front differential that other models have had problems with. Erratic or no engagement. The 300 and 400 used the same part,but hard to find cheaper aluminum replacements than this. But should solve your problems. Polaris Sportsman 300 Front Differential Roller Cage Sprague 2008 2010 | eBay

 

Thanks For the link and the information OPT! I was kind of worried that's what the problem was. Guess I will be to save up some pennies and get that part.

Is there anything else I should replace while I am in there and what are some other signs I should watch for while I have it apart. Worried about my aggressive "checking" causing other damage. Don't want anything else failing.

Thanks again!!!

 

This has happened several times to people while on ice. It just causes a violent engagement of the awd and tears up roller cages when the wheels are slipping. They already have a bad rep on cracking even on good terrain. You'll probably know fairly quick if the prop itself or u-joints are damaged when you remove it/slide it back to be able to pull the front diff. Once inside you can check over the ring and pinion gears also. Hopefully no other damage.