Workaholic,
You are on the right track by doing your homework. After I talk to Polaris I might have a change of heart. I'll post and let everyone know my results. In the past I've been able to talk to a Polaris tech which is a good sign, because it is rare to actually speak to other brands techs. Fingers crossed...

 

I contacted Polaris and spoke with a rep. He said in a nice way, "It's a dealer issue." He said if you put the wrong fluid in the front diff, it will cause damage. I'm going to contact the dealer who put the wrong fluid in and see what my next step will be.

 

Yup keep calling them up until they get annoyed and fix the problem they caused.
I had my cd player faceplate in my car scratched not too long ago when i had the pioneer company fix the cd player.. i get it back with an ugly deep scratch on it. I sent it back.. month n a half later i called again and i got pissed off pretty bad at the guy.. he said he was sorry and he would fix the problem.. 2 days later i got a brand new faceplate.. persistance pays off.. in most cases.

 

Today I drove to the Polaris Dealer and talked to him about what happened to my ATV. He agreed with me and said it looks like they made a mistake and put in the wrong fluid. I was all ready to argue with him but he was very nice and wanted to resolve the issue. I don't know what to say except, I respect a person who admits when they make a mistake. He advised his mechanics of the fluid problem and showed concerned that they may have put the wrong fluid in other ATV's and I think he said he was going to check his invoices and see. I'll post with the results when the ATV is fixed. The mechanic personally said he was sorry and will take extra care when fixing it.

Now that I was unable to vent my frustrations I'll have to go out and kill some small animals (just kidding). Actually I have to go apologise to my wife who has been very supportive while I've been a crazed lunatic over this.

 

Glad your dealer came through, let us know how it all turns out.

 

Dealer got the Hillard removed and says, "Lots of metal shavings." I'm going to take a look today.

 

When I spoke with the mechanic on the phone, (as he was taking the hillard apart) he was talking about metal shavings and heat damage. Now that I went down to see the hillard, he said there was very little damage and will only be replacing the plastic cage and some other flat ring thing. When I asked him about the plastic cage, he said It's better than the aluminium cage that I heard of. I hope with the heat, it didn't change the temper of the metal parts. I'm starting to get a bad feeling that the dealer is now trying to save money at my expence.

 

These problems are not too common. They switched to the newer front drive system because of the old style hubs and their problems.

I use Castrol Syntec 5w50 in the new front ends and I have never seen a problem out of them so far.

I think 90 weight is just too thick for the 4wd unit to work correctly.

 

Makes me wonder why people think I am crazy when I insist that I either will do the work myself or if anyone does it, I watch.

Kinda like sex. Maybe if I trust the girl, I might let her get away with puting a blindfold on me once in a long while but for the most part, I like to watch what happens.

 

Well heres my 2 Cents worth,Polaris will stand behind their product!
Call the head office and politely raise hell.
I have an 04\600 and they are still covering my bike under warrenty.Im into my second full engine rebuild and I'm not paying for anything!
If you squek they will oil you !!!!
The dealer has to be on your side as well or else they will tell you where to go.If your dealer won't help you find another one>
Ive had the following parts replaced after warrenty\ Coil, stator, CDI, Clutch,Front strut,4 belts,and now my second engine rebuild,New Cylinders,Head etc.
They will support you if you are using the right terminology.I love my polaris's and i would still recommend them especially after more than 2 years out of warrenty they are still trying to fix her!!!
Anyway Just Givver