I have 2004 Sportsman 700. I recently changed the front end lube. I filled to the bottom of the fill plug like you are suppose to. I took a ride last weekend and noticed that it seemed like the front end would engage with the AWD off. Today, I was looking over it and placed my ATV on jack stands and with the AWD off, the front end is engaging and disengaging? What is the deal? I pulled the plug and the oil is full. Need a quick fix as I am scheduled for a massive ride tomorrow....

Thanks

 

Sounds like you might have put the wrong oil in.

 

I put the Pure Polaris Front ATV Oil in it. I got it from the dealership. Maybe too much?? When I pull the plug, nothing really runs out, but I did put the recommended 5 oz. in it.

 

So, I put my quad up on jack stands and in low gear with AWD off, it will not engage until I hit high RPM's and then it engages pretty hard. In High gear, it engages all 4 wheels no matter what the switch says...any ideas? Something I can try to eliminate this problem. Manual is of no help...

 

Make sure you used the hub fluid and not the front gearcase oil....

 

I used the front gearcase oil they gave me. Is there different front end lubes???

 

This is from my manual for my 03 700


Front Gearcase Specifications
Specified Lubricant
Premium Demand Drive Hub Fluid
(PN 28716547)
Capacity .............5.0 oz

 

Yes there are different fluids and it's confusing if you don't pay attention, don't rely on the dealer to give you the right stuff, you need to know. The machines with the locking hubs at the wheels take front gearcase fluid in the front diff, this is now called angle drive fluid which also is used in the rear diffs on the Sportsmans. The hub fluid is needed in the front gearcase's that also have the internal hillyards. You need to flush out your gearcase and get the right fluid in there, also the jack method you used for testing is hard on the hillyards if they have a problem. If you haven't broke the cage yet you will with the slamming when they lock up.....

 

They gave me 2871653--Atv Front Geardrive Fluid. SO--how much damage do you think I have done? I have ridden about 20 miles on it...noticing something was wrong last weekend..that is why I dug into it. Can I drain and flush the front end and get the right fluid put in?? I suppose I have to use the Polaris stuff which means a trip to a dealer 60 miles away.

 

Hopefully you haven't done any damage, the fluid you put in is too thick hence your problem. I've read type F automatic trans fluid will work also but I haven't used it. If your getting the Polaris stuff then get several bottles and change it a couple times and with luck the problem will go away.....