Hi everyone, new here..hope I can help, but first I need some. I have an 02 Sportsman 400. I have read every post on the subject of the front hubs on the AWD Polaris and have tried everything, so here we go. Basically, one front hub will LOOSE ENGAGEMENT...not the A. plate, not the hilliard clutch, not the bearings, good magnetic coil, not the switch, not the tension on the castle nut, not the fluid. I bought this machine used and cannot verify for sure that all four wheels have ever driven this machine at the same time. I have troubleshot from one front hub to the other and can move the disengagement from one side to the other by just switching just the hub assembly from one side to the other. I swear I can feel the clutch inside the hub rotating, but I can't see any wear on the inside of the hilliard clutch or on the inside of the hub. A loose garter spring would only make it easier to engage. I really don't want to replace anything. I guess I'm looking for a miracle. I've had both front hubs apart a million times and know them well, but what the....Is it possible that the inside of the hub was machined out too much at the factory and the expansion of the clutch is not enough for the hub to lock? I climb out of a lot of mud holes and need all four wheels spinning or I'm screwed. I like having a winch, but...

 

if the problem changes from side to side as you move the hub to the other side i would say you found your problem have you checked the inside diam of the two hubs with a micrometer? find a buddy with the same setup and try the hub of another bike to se if its still there good luck