i have a 97' magnum 425 and the 4x4 system is not working.when i engage the 4x4 after a little spinning of the wheels one of the front wheels locks in but the other wheel never does.also when i let off the gas and come to a stop the front wheel falls out of 4x4 and i have to everything all over again just so i can get that third wheel to start spinning again.any suggestions on whats wrong and how would i go about fixing this problem?thanks for any suggestions.

 

that stinks. cant help ya there, just make sure u dont find yurself in a waist deep mud hole[img]i/expressions/face-icon-small-shocked.gif[/img]

 

Most likely culprit is there is little or no fluid left in the hubs.
Each hub takes a few ounces of synthetic ATF. I use Mobil 1.
Pull the allen screw in the hub and rotate to the 6:00 position, and drain.
Rotate the hub so the screw is at the 3:00 position, and fill until it drains back out.
Clean up and try it again.
If that doesnt work, start the quad, put in 4x4. then take a screwdriver and touch it to the inside edge of the hub . You should feel a magnetic field pulling on the screwdriver. If you do you will need to disassemble the hubs and clean the rollers on the Hillard Clutch up. Reassemble, add fluid, and try again.

If no magnetic field, ohm out the hub coils to see if they are bad.

Good luck, take your time its pretty easy.

 

If the hub fluid is not the problem, and the hub coil checks out good, check your armature plate located behind the hillard clutcj in the hub. If they are groved or bent the least bit, the hub wont engage. A new armature plate is $8. Just replaced one last week on my scrammy and it fixed the 3 wheel drive problem

 

just replaced fuild in hubs no change we will try those other things and let u know thanks

 

Track those two tiny wires that lead to the hub that doesn't drive. Chances are one is broke.

 

could it be the switch??

 

I think that if the light on the switch works, its probably not that. And if awd works at all it probably isnt the switch.

Make sure the castle nut in the hub is torqued correctly, too little or too much and the clutch wont operate properly.

 

we went to work on the polaris 425 again today, found that the switch in the shifter was bad replaced it 4 wheel drive works and the AWD light works again

thank for your help

 

So it was the sensor in the range selector, not the AWD switch, right?