I have a 2004.5 400 sportsman and noticed that the front wheels want to lock in with the AWD switch in the off position and the LCD display also indicates it is disengaged. I know the front wheels should engage when the AWD system is turned on, but only the back two wheels should spin when the system is off correct!! I have asked a few dealers what could cause this and I have gotten two replies. One stated it could be the armature in the front differential has became magnitised and the other stated there is an adjustment on the front differential that could correct this problem. I am hoping it is just an adjustment. If anyone knows anything concerning this problem or if anyone knows how to make this adjustment the advice would be greatly appriciated

 

Polaris is aware of this problem and is trying to figure out a fix

Since they changed the front set up it’s been a problem …..some real world dynamics working on the clutch in this set up……stay in contact with your dealer!

 

I've spent so much time learning how the old outboard hubs work, I never took the time to look at my 04.5's center hubs. Is there one hub that engages both wheels, or do they still engage separately? I would imagine separately, but I've never gotten one side jammed in AWD on my 04.5 yet; my 250's do it all the time. Is the hub design still basically the same, or is it really changed?

TIA
Tyler

 

I'm not sure how the old systems worked (this is my first). My 04.5 has a differential in the center, on the front of the atm and appears that it locks in both wheels. So to answer you question I believe it only has one hub to lock in both wheels. I've been told by a few dealers that there is an armature inside this diferential that will become magnitised if there is not enough oil in the differential causing the atm to stay in AWD at all times.

 

That's what I figured. I'll look at an exploded view in the service manual. Its not a differential in the front though.

Actually, it must be two separate hubs, because with just one, it would have to lock the front axle AND engage the front wheels.
If you don't follow that^^, don't worry, I am thinking out loud....

Tyler