On my first post when I tested the awd out the ice was shiny and very slick. I went back out to the same ice yesterday and it was sunny out and the ice had some slush on it, not nearly as slick as the day before. I tested the awd the same way, turned it on and drove around and then stopped and turned the awd off. I drove slow for the first couple of feet and it didn't engage at all from then on. I tried it about four times like that and it worked flawlessly. Just my thought, but when you turn the awd off and when the conditions are very slick maybe the sensors sense the rear wheels are still slipping and won't disengage until their is no slipping. If you read your owners manual if you turn off your awd and you front wheels are slipping then it won't disengage until they don't slip anymore. Not sure if I made any sense, but this seems to be what might be happening to my quad. Let me know what you guys think.

 

Jeff are you sure the dealer even put any hub fluid in, they are shipped with no fluids, might be something you want to check before too long, you did say you only have 10mi on it. I have yet to have this problem or any for that matter on my 04 700 EFI with over 900mi. on it. I do change my fluids regularly as well too. There is so little fluid in the hub and it will breakdown and become very sticky and cause engagement and disengagemant problems.

 

I just got back from the dealer on Friday for the same thing, plus the fan and radiator. He said my armature plate in the front differential had got magnetized somehow, causing it to stay locked in. He replaced the plate and the outer diff. cover, and said that should remedy the problem. It did in his parking lot, but I haven't had time to try it at home. He said he had saw that happening before, doesn't know why they do it, but mine wasn't the first. Good thing it was warranty, he said I was looking at around 6-800 dollars for the parts and labor!!

 

I bet that the labor would have been a pretty good chunk of that. When the warrantee went out, the service manual came in. For me anyways.

 

My 04.5 600 has this problem. Noticed it a couple weeks ago. I have change the fluid twice. Still engages whenever it feels like it. I will never buy a polaris again. more problems than anything else.

 

it wouldnt be all the fun to ride at first but the more u lugged the thing around ur arms would be ripped, good idea huh, lol jk[img]i/expressions/face-icon-small-tongue.gif[/img]

 

My dealer is going to be replacing the entire front gearcase to fix mine. It is under extended warranty.