hi i have a 2006 500 efi sportsman,the 4x4 is on all the time.can someone please help me solve this problem.i tested the engagement switch,it seems fine. the oil in the front diff is full and newer.

 

Either the armature plate is magnetized in the front diff or the plastic roll cage is broken,or both. Upgrade aluminum roll cages are on ebay and if you have to tear into the front diff,this is the way to go. Item#10 is the roll cage.#31 is the armature plate.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Plenty of roll cages on ebay.Polaris Sportsman 450 500 700 800 Aluminum Front Differential Roll Cage Sprague | eBay

 

If the 4x4 was engaged at all times the ATV would be very hard to impossible to steer. It would be like having diff lock on at all times. Polaris does not have a 3wd mode with a limited slip front end like other brands for easy steering.
It's in true AWD or 2wd with no inbetween.

 

I took it that that was what he was talking about. I've had plastic roll cages break and lock inside the ring gear housing causing one drive shaft or the other to stay engaged.

 

thanks a bunch OPT, ya great quad but very heavy steering. i will tear into this thing this weekend and i will post what i find.great site guys.oh if you have any tips on removal of the dif,that also will be greatly appreciated

 

Here's one guys video on the 2006 front diff. It is a little cramped because of the radiator. The Rzr is actually easier to remove because the radiator is higher,but this video shows what happens to a lot of roll cages. Some just crack and lock,others just shatter.

 

again thanks to all,what a great website.you guys are so helpful.

 

update , i took it apart this weekend ,the cage looks perfect, no cracks no burrs, moves very smooth the armature plate is fine it has 2 track marks ,even all around, i powered up the magnet with the cover off and it grabs the plate very well but when you power down it takes maybe 10 or more seconds for it to fully release.i watched the videos you sent..thanks for that..i put the cover on and powered up and it locked both sides as it should when i powered off it did not really release it. i turned the input shaft back and forth a few times and then it released.also the armature plate is not magnetized but the coil is slightly magnetized all the time.you can feel it when you lift the plate off. sorry for the long text.

 

i have an update on this thing ,pulled the front diff out, the roll cage seems perfect no scars very smooth operation.the armature plate is flat and has 2 even rings around it looks good and is not magnetized.so far everything looks good. now,, the coil reads 27 ohms and the magnet on power up grabs very well but releases very slow. the coil is slightly magnetized with no power to it. your input is very much appreciated