First of all, I never had any problems until I tried to "fix" the AWD reverse override on my 2002 SP 500. When I did it, one of the front hubs would stay locked in in forward, after backing up w/ AWD on. This was very aggravating to me, so I put the wires back together. Now, one hub will always lock up in reverse, even w/o the back wheels actually spinning, or holding down the override button. When I had it at the dealer for HD springs, I asked him to check it and he said he put new fluid in it. It still locked in, and I took it back, and he changed the fluid again, this time he found the tapered outer bearing had a huge dent in it, so he changed it. I think he actually dented it when he changed the springs, because I've never had the hub cover off, so it wasn't done by me. He said it came like that from the factory, and that's what was causing my problem. Well, it's still not fixed. It does it sometimes in forward, but mostly in reverse, and mostly the right front hub, but occasionally the left will lock in. I'm at the end of my rope, I love my four-wheeler, but am tired of not being able to back up w/o having the bars jerk to the right, and my dealer can't seem to fix it, so does anyone have any ideas, maybe something I could ask him to check the next time he has it? I read somewhere one time about something in the hub becoming magnetized, causing it to stay locked in, even after electricity was turned off. Please, any insight will help, Someone has got to know something that will help me. By the way, otherwise, I love my Polaris, and wouldn't ake any other brand. Thanks in advance.

Andy Stewart

 

When did you buy it?
Do you still have the warrenty?
If so tell them you want it fixed,
if they cant(wont) do it CALL POLARIS
Have you tried taking it to another dealer?

 

I bought it new on Oct 1, last year, and it came with a 1 yr. warranty, so it's still covered. I have to work alot this week, so I think I'll call him and tell him I'll bring it back and to keep it until it's fixed. I'll try that before I go to another dealer. Does anyone know if another dealer will honour the warranty ? I found where the wires split off to go to each hub, there's a big cluster of brown and gray wires that come together, and two different "plugs" go out, each one has a brown and gray wire, each leading to a hub. I took them apart a hooked it to a volt meter. There is power going out the plugs like it should, ex: in L or H, and AWD switch on, power goes down the wires, pull it into N or R, turn off AWD and power is cut, but comes back on in reverse when the override is held down w/ AWD on again. These are the wires going down to the hubs, so I have now isolated it to the hubs themself, not some type of electrical problem up above. I'm going to call him first thing Tuesday, and tell him I'm bringing it to him, this will be the fourth trip for this problem, and I hope he can fix it this time.

Andy

 

As long as the warranty papers were properly filled out, any dealer should be able to do warranty work.
If it were me, I would try another dealer & see if they can fix it under warranty.

Farmr

 

Tell him to change out the armature plates in both hubs. They're about $4 each, and they are the part that can become magnetized and cause problems. If it's not that, there are only a couple other problems it could be. If the spindle nut is not torqued correctly, or the garter spring that holds the rollers in could be damaged. Either way, the hub mechanism is very simple. Good Luck,

Waylan