Hi,
I have a 2003 Sportsman 400. When i first bought it in winter of 2002 I had something go in the right front wheel that stopped if from engaging with the AWD system. The dealer fixed it under warranty and said it was something to do with the electronic AWD part of the right front hub. Well today I am out breaking trails and was getting stuck alot when I finally realized my right front wheel was not spinning with the left front wheel. I am thinking that the same problem exists that I had when I first got this ATV in winter of 2002. I have no more warranty so I will have to fix it myself. Does anyone have any idea what may be wrong and where I may find a manual for this ATV with info to fix this problem. Thanks for all your help.

 

Check the hub fluid

 

Ok checked fluid, didn't look good. Fluid was very black and had a lot of filings in it, smelled very burnt.
Checked with dealer they say probably the clutches are burnt out and would have to buy a whole hub unit cannot rebuild hub. Well I guess it's time to buy a do-it-yourself book. Thanks for taking the time to reply to my inquiry.

" littlered4x4"

 

Change the hub fluid afew times and see how it acts.And you CAN rebuild the hubs.

 

Thanks alot, I'll change the fluid and see what happens. If I need to rebuild I'll let you know maybe someone can let me know where to get parts.

thanks,

 

Here is the repair manual Sportsman 400

 

Had a similar problem with my SP 500, when I would disengage AWD, it would somethimes stick and pull really hard to one side. Found both front hubs to have damn near no fluid in them, smelled burnt. So I added more than the needed amount of fluid and it has acted correctly since. I am planning on replacing the fluid soon and will only put the correct amount in this time.

SLG

 

THere's quite a few posts on this topic, a search should help you a lot. Look for things like "4wd not working" or handlebars "pull to one side". Oftentimes this brings up threads concerning the problem you have.
If you get a repair manual (you should) you should get the Polaris one, not a third party one. Very complete diagrams and instructions.

Anyone else think that a sticky should be made here with information on how the Polaris AWD system works, as well as some common problems and solutions, like hubs sticking or not engaging? It comes up so often, and its tough to explain the system when writing shorthand in a reply.

 

Thanks a lot for all your great input. I am ordering a Polaris manual. I have not had time to change my diff fluid yet but will post results as soon as done so we can keep everyone up-to-date on this problem.

littlered4x4

 

Hi all,

Just wanted to let you know how this turned out. The problem with the right front wheel not locking in was a wiring problem to the front hub no big deal. The problem with the filings coming out with the oil on the other hand was a bent axle. Thanks again for all your input, I did learn a lot from this experience as I had taken apart the entire front hub assembly myself and had it inspected by the dealer, he was very helpful in assiting me in determining the problem. We wish you all a safe and happy holiday season

littlered4x4