After a service which included the front diff fluid change, I told the dealer that after switching from 4x4 to 2wd, it would stay in 4wd. He said it was normal and sometimes I might have to stop and go in reverse to disingage the 4x4, again it was normal and nothing is wrong. Now, while in 2wd, the 4x4 engages and disingages intermitantly with the switch in 2wd. Now that my warranty is up, I have a bad feeling it is now not normal.

It seems the 4x4 issue started when I got a $170.00 dealer service that included the front diff.. I only have about 90 miles and less than 100 hrs on my ATV.

 

AAAAAAAA ya!!! The gauge package is there for a reason. To tell you if something is wrong. If you can't read the gauge because it's all fogged up you can't tell if something is wrong. Let me put it to you this way. You just bought a brand new 50K lexus and the dealer told you it's normal for the gauges to fog up. Would you accept that?

About the 4x issue. I don't have a Polaris so I can't speak much about it. I can tell you that Polaris has issues with fluid in the hub. From what I have read, it has to be very clean, the right type, and the right amount.
Someone else will be able to talk to this issue better than I.

 

As far as the fog that is not normal and should have been fixed.

With the 4x4 I can help you out a little bit. I had a simialar problem with my 2004.5 500 HO. I had bought it brand new and took it home and noticed that the awd would kick in even if the switch was in 2wd...I thought nothing of it (after all it was brand new and I had never owned a Polaris or even an ATV) a couple of months ago I came across a post on a forum and found out that it was never suppose to do that. So I took it into my dealer and asked said that it should be covered under warranty even though it was past the 6 months because it was like that since I bought it so how was I suppose to know it was wrong. Well over 3 weeks of fighting with them they and many new parts they fixed it. All that it was was a piece of plastic in the gearcase that wasn't allowing it to come in and out of AWD. It ended up costing me alot and I also had to cancel about 4 day trips because it was in the shop so long.

I have also heard that alot of the time it is the gear fluid so change that first.

Hope this helps.

 

Thanks for the help, I think I'll call Polaris now and hope I can get this issue fixed, I mean with the dealer... Thanks again.

 

Make sure you have the correct fluid (premium Demand Drive ) and correct AMOUNT in the front diff.
mine never does this , not normal but does occur.

The instrument panel should not fog but some do.

Jim

 

The front diff is allways ingauged. The awd works off the front wheel hubs. You need to check the front hub fluid in them an change it. Polaris uses an eletromagnet setup in hubs to grab the axle when the rear slips a bit an the front axles spine faster then the front tire. There should be a diagram that shows how it works.

 

I don't think there is any fluid in the front hubs on an 04.5. that changed a few years ago. If there is I have never changed the wifes.

 

04.5 and up single cylinder sportsmans have the inboard hub, like on the twins. No more outboard hubs. The oil is now located in the front gearcase (which is just like the hub, except before the driveshafts). Scramblers still have outboard hubs.

 

Yes you are correct tyler... now for a fix redmtn drain you hub fluid completely out, take both the drain plug and the fill plug out and let it drain, replace the drain plug and fill the front gearcase until the fluid runs out the hole on the side


with the 4x4 systems on the sportsman there is a spline that will grab the axle, when this happens it gets electronically charged... sometimes you will need to drive 5 to 10 feet after turning the 4x4 system off without spinning the rear tires before the front end will disengage completely

if this doesnt correct your problem i would contact your dealer and let him know about it.

 

All the twins have the centralized hub with the 2002 700 and up, the rest of the sportsmans follow in 2004.5.

Jim [img]i/expressions/face-icon-small-wink.gif[/img]