I know that you have this 20% or 1/5 thing in your head.........You are slightly confused, to say the least. First off I too went to the "polaris parts manual" it says nothing about the gear ratios. So I ask again for a THIRD time, where are you getting this imfo? The FACT is that this 20% or 1/5 thing works like many of todays AWD cars and trucks. THERE IS NO GEAR RATIO DIFFERENCE NEEDED TO MAKE THIS WORK.........PERIOD...................It works in this maner, once the the output shaft going to the front end spins 1/ 5 of a rotation or your magic 20% number..... The clutching mech. is allowed to engauge. For all you out there this is not "MAGIC", this is engineering..... The thought that you think there is a gear ratio difference, is like using a chain saw to cut a mortis.

 

Sorry buddy, no... you are wrong. Go back to your friend.. the engineer at Polaris. Ask him to ask someone at Polaris who knows. BTW.. the magic 1/5 of a revolution was atually 1/6 of a revolution on the older quads because the over running clutch was hexagonal. Furthermore, the rollers will actually engage in about 1/12 of a revolution with this hexagonal unit. So you don't have any magic 20%. It is more like 8%. And even if you don't beleive me.. you can read a parts manual that lists all the gear ratios and you can calculate it yourself. BTW.. the Polaris AWD is nothing like AWD cars and trucks, so please don't try to compare it to them. So if you think there is no gear ratio difference, then tell us the front and rear axle ratio of the 2005 EFI 800 Sportsman.
Bryce

 

YOU ARE WRONG... YOU TELL US THE GEAR RATIOS... YOU seem to be able to find them... YOU seem to have all the anwsers... YOU tell us... And if all this gear ratio **** is for a 4x4 scrambler, YOU know the one with a CHAIN then YOU would be correct about the ratios... however WE are all taking about a sportsman 2002-2006. YOU may want to get an education before YOU run YOUR mouth...and by the way it is EXSACTLY like new AWD cars and trucks...BY THE WAY WHAT IS YOUR BACKGROUND IN? YOU seem to know all...

 

The rear axle ratio is 10 teeth on the pinion, 31 teeth on the ring gear for a gear ratio of 3.1 The front axle has 11 teeth on the pinion and about 45 teeth on the ring gear for a ratio of 4.09. The gear ratio difference is (4.09-3.1)/4.09 or 24%. It is common knowlege on this forum that the Polaris has a 20% difference betwen the front and rear end. On the scrambler, it is a complicated set of ratios. On the Sportsmans, it is a simple difference in ratios between the front and rear axle. The reason the Polaris AWD is so different than a car is that the AWD drive system on a car requires a center differential to allow the front and rear wheels to turn at a different rate going around corners. The Polaris AWD has no center differential. It depends on the overuning clutches to allow the wheels to run at different speeds. This is also what sets apart the Polaris system from all the other ATVs.
Bryce

 

sth, as politely as I can say it, you don't know what you are talking about.

Polaris AWD does indeed rely ENTIRELY on gear ratios, as the heart of the system is the Hilliard Overrun Clutch. And it is nothing like AWD in cars and trucks. If anything, the Polaris system is like automatic part-time 4wd, not AWD. When engaged, there is no differential between the front and rear axles, where an AWD road vehicle has a viscous-coupling central differential to allow for wheel speed differences.

If you have a Polaris ATV, put it on jackstands and put it in AWD with the key on. WIth your hand, spin the rear tire forward until the AWD engages and the front tires start turning. Now, with chalk, mark the bottom of one rear and one front tire. Using the chalk as a guide, rotate the rear tire 1 revolution (until the chalk is back at the bottom). Now look at the front. The front tire has turned LESS than one revolution, showing that there are different gear ratios between the front and rear axles.

 

Thanks for clearing that up Tyler [img]i/expressions/face-icon-small-smile.gif[/img]
Bryce

 

You seemed to have it pretty much under control, but I miss our discussions [img]i/expressions/face-icon-small-happy.gif[/img].

 

LOL.. I know what you mean.. I only see so many of the technical discussions.. You know.. the ones that get the brain juices flowing [img]i/expressions/face-icon-small-smile.gif[/img]

 

Dim wits

 

BTW Zbart1.. I thought your 4 step process for debugging the problem was quite good. [img]i/expressions/face-icon-small-smile.gif[/img]
Bryce