I just purchased a used sportsman 500. The left front hub will not engage in AWD. If I torque the spindle nut tighter than the recommended specs, the wheel will turn when placed in AWD (while on jacks), but the Hillard clutch is still not fully engaged. I can stop the wheel with my hand.

I replaced the inner and outer strut seals and the hub seal. Whil I was at it, I replaced the bearings and bearing races. I have still have the same problem. I did notice that the armature plate was slightly bent (oh so slightly).

I took apart the clutch and cleaned it. It tests good. The spring is strong and the cam and rollers will engage/disengage without any hangups.

Any ideas? Am I missing anything?

 

I own a Sportsman 500 also and I am having the same problem. Can anyone help us

 

My scrambler 400 did the same thing. Polaris didn't leave much room for the wires, or slack for that matter. I found that I had a broken wire by the strut. I sottered it back together and used shrink tape to protect it. Check there first, for broken wires. Then check on the power panel, sometimes the terminal will break off or wire will pull out of the terminal. Easy fix!

 

ProXScrambler,

The wiring checks out okay. The left and right magnetic coils ohm out at ~25 Ohms, no shorts, no opens. Voltage is present to both hubs.

 

Hum, then I really don't have a clue what might be wrong with it. Sorry I couldn't help out.

 

Here are a few possibilities.

1) How about the magnet coil gap? The armature plate is supposed to touch both the inner and outer magnet sleeves at the same time. They must be set as clost to even as they can be. I believe the wear sleeve where the seal rides is movable, be sure it is positioned as close to even as possible.

2) If the armature plate is bent even a little, this can cause the problem.

3) On the armature plate, there a 3 little 'tabs' that MUST engage in the 'notches' of the piece it fits against (the cam/roller piece). If it is assembled improperly, or the bearing somehow gets loose enough so they don't, you usually lose 4wd. Sorry to say, but if the tabs are bent or flattened, the only real fix is to replace the plate.

4) If you have it apart again, turn on the 4wd, and verify the magnet works. I have seen where there was no apparent broken wire, yet the magnet had no power. See if it will 'grab' a screwdriver or something. Sometimes the wire gets pinched where it goes through the strut housing, breakin the wire strands internally, but the outer insulation will not be cut through. Rare, but it happens.

Good luck

 

get a 700

 

The armature plates are very cheap. If they show any wear at all, I just replace them. if they are bent slightly, this is probably your problem. I use a bit of axel grease to insure they stay in place while I slide the hub on.

Greg

 

You are right and thanks, gregsims! The problem lies in the armature plate, a $3.75 piece. I switched the right to the left and voila, the left hub works in AWD and the right hub quit working. I ordered replacements for both sides.

 

Put the bike up and go to work!!!!I`m glad you got your problem solved,NOW GET TO WORK!