97 sportsman 400, I baught it used and am trying to get it right.
1. Left front hub will not engage in 4x4 it will read 24 oms through the coil and has power coming from the switch.
I have changed the hub fluid twice.

2. I was going to change the swingarm bushings but found them in good shape, the problem was both lock washers on the swing arm bolts were worn out and the bolts were loose. I made new lock washers and reinstalled the swing arm. Problem the bolts are suppose to fit in a bushing in the tranny, should these fit tight or have clearence. If they need to be replaced how do you get them out while still in the atv?.

3. When I pulled the drive clutch the white bushing was in bad shape worn out . What caused this?

4. How do you check drive clutch wear, My clutch is smooth but at the shaft it is a little thicker, stickes out further.

 

Sorry i couldn't help ... but welcome to the forums!

 

welcome troyson
1. you're probably going to need to tear the hub apart and inspect it. could be the roller cage, armature plate, plate / coil spacing, or even the torque on the bearings.
2 sorry, i havent found any easy way to get these out. in or out of the bike. if you replaced the bolts and there is still alot of play in them you will need to replaced the bushings.
3 & 4 if the bushing was worn and looked melted its from excessive heat from belt slipping. and this sound like the case if the clutch is worn at the inner most part. the clutch face has worn some, could be several reasons - running hi range at very low speed, dirt in clutch cover, etc.

 

If it dont rain I will tear the hub down today. I will also order the swingarm bushings and new bolts and clutch bushings today.

Thanks Troy

 

Make sure to watch the order you pull the hub pieces out in! There are a lot, and they all look the same [img]i/expressions/face-icon-small-confused.gif[/img]. Check the torque on that castle nut in the hub, it needs to be just right, I forget the spec though.