Been trying to get some maintenance dealt with on my machine. New rear drive chain. New drive Belt. New brake pads up front. changed hub oil. Changed the gear case oil, using Polaris GC oil. Changed counterbalance oil using mobil 1 10/30. Removed shifter assy, added 10/30 mobil 1 oil. checked the selector switch, works fine.

Front wheels just don't respond. I have read as many old threads as I could find.

Removed front hubs, made sure all was clean, retorqued at 165 inch pounds, loosened, then final torque at about 120 IPS. Armature plate not bent. laid it on a sheet of glass. has the magnet rub marks though. When the AWD switch is on the magnets really grab. No wear on bearings or axle. One castle nut seems a bit cross threaded but it works fine closer into the bearing washer. Cleaned out with new Polaris Hub Fluid twice, very clean now, no gunk on the allen bolt.

Jacked up the wheels, ran in AWD, front wheels won't turn.

AWD light on handlebar works, magnets in hub work when switch is pushed in,
Reverse light Does Not work, not when in reverse, not at all.
Neutral Light stays on in Forward, high and low range

Previous owner bypassed the reverse override switch. no AWD even if hold button in in reverse. (did not know until reading forum that was necesary)

Lights on bar between ignition and choke that I see work are; overheating light, bright headlight indicator, Neutral. No others.

I have not removed the gas tank to check the wiring pod. Not Yet...


I have no shop manual for this thing yet. But am looking. I have not adjusted the drive chain or the front chain. Would this matter?
I have not adjusted the shifter linkage. When I press fwd on the shifter lever the neutral light goes out, just won't stay off.

Dealer only had one new armature plate in stock. will get another just to be sure. seems like Hillard Clutch works okay. All splines on axle and in clutch look like new.

Seems like the shifter switch stem-arm is not tight enough in the shifter ball. Hate to go monkeying around with the linkage for no reason.

If the magnets are energized, shouldn't the whole thing work?

I am running lower air pressure in the rear tires than I have been. Evidently not critical since when up on jackstands the front wheels still won't drive.

Any ideas appreciated greatly.

lester

 

If your nuetral light is staying on when shifted out of nuetral the gear position switch is bad or the shifter needs adjustment. I would lean toward the switch itself as they have had some problems with these. The unit has to be shifted into a forward gear for the AWD to work and the gear position switch is what controls that.

 

The shifter switch worked fine; when I moved the switch-arm up or down manually, when I had the shifter removed.

I guess I will have to try adjusting the shift link arms, and if that doesn't work, try holding the switch while the rig is running on the jack stands, and then engaging the AWD button.

thanks for your reply.

 

Yeah i think for the awd to work it needs to be (or at least think) it is in gear. if reverse, it also needs the override button depressed. if your neutral lights on, then awd wont engage.
But as with any thread i respond to, the key words here are I think

 

dismounted the shifter; switch has one burned wire. $80 and 160 miles to get one. hopefully, back up to speed soon.

thanks for all the replies.

 

I am having same problem with dads 97 6x6 right now. The switch lights up fine in high, low and rev w/OR pushed and goes out in neutral. I have taken apart both hubs, changed fluids 2 times, but still won't work. Do you think I could have the same problem?

 

Just an update, back from the Polaris dealer, and installed my new selector switch. I now have a reverse light.

Still had no front wheel drive.

Further inspection showed that the front drive cog is missing. Bolt must've come loose and it spun off, somewhere.
Lesson learned; don't overlook the obvious. So back to the dealer. At least there are 3 within 80 miles of me.

The selector switch was shot anyway.
All will be right soon.

Got the new Ramsey Winch working fine. Once I get the AWD working; let it snow! Got the plow all ready to go.

More to come, I'm sure.