has any one ever checked the gap between the inner and outer poles on the AWD system? it is suppose to be .0005"(.025mm), or basicaly almost no gap at all, I can see no gap on either side of mine, is this nomal, the hubs seem to engage eradically, when in 4wd, making the handle bars jerk back and forth. All the parts seem in order, could it be a pole gap issue? Any related experinces would help . thanks

 

Gap is .001 ( one one thousands of an inch) With no grease anywhere!!!! Only Polaris Ft hub 4x4 oil or Snythetic transmission oil. Use Polaris oil. Remember clean is the word here. Get oil rings and seals out of way and use a high flash solivent or contact cleaner to get everthing spotless. Then reassemble and add oil. Set Allen screw hole in Ft hub at 75 degree angle, fill oil until it runs out. Then wait awhile and you can move hub to 90 degrees and let a little more oil run out. Put in Allen screw and your done.

 

I kept having the same problem with mine check your springs on the inside they get wore out and won't hold the bearings in or you could do like i did rip all that crap out and put it the rafters then go do you some wheelie ridin" YEEEEEHAAAWW!!!!!!!

DAMAGE

 

I have thought about that, what did you do , remove the rollers or the whole cage.