Were the hitch, a-arm mount and frame come together. On the rear of the machine tight on the welds.

 

No one has really said which of the rear lower A-arm bolts is breaking, the inner on the frame tab or the outer on the hub, but I’m assuming it’s the outer on the hub you all are referring too.

Just keep in mind as you check your machine for loose bolts, once you turn a bolt the seal on the thread locker is broken. Of course, if you find one loose the seal is likely already broken unless it came from the factory that way. The point is, be sure to put thread locker on all these suspension bolts if you turn them for any reason. As some of you know from previous threads I lost a front bolt out of the rear lower A-arm where it attaches to the frame a while back. It didn’t break, it fell out on the trail. Twisted the bejesus out of the upper A-arm when it let go. Polaris replaced all the affected parts under warranty but it sure made for a lot of extra work to get the machine back on the trail three days into an eight day riding vacation.

 

Its the right rear outer bolt that breaks

 

I've seen a lot of the bolt breaking problems on the forums recently Jeremy but the AWD engagement problem has been sporadic over the years, mainly a cause of the incorrect fluid being used or amount used, too little or too much fluid.

The Hilliard front diff takes 5 oz. of the Polaris Premium Demand Drive fluid and this needs to be adhered to strictly.

I'm sure most of this you and HSP already know.

Jim

 

Our awd problem was the palstic housing had shattered liek it's supposed to when guys go into awd at wide open throttle in the mud. Replaces it and no problems since.

 

speed. as of 3800 miles i have broken the lower outer right rear bolt 4 times. the first 3 were the smaller 3/8 bolts the last one was the 7/16 as i replaced my hubs with the newer hubs with bigger hardware thinking this would solve problem but it still breaks. the bike isnt abused but i ride it fairly hard

 

 

Hey guy's and gal's.
Speed werx, just a little heads up on your front carrier breaking scenario.
The system works well but I found out the hard way that if you are in two wheel drive and depress the overide switch when in reverse and punch it the front diff will engage, the only problem is it engages when your around 3500 RPM and it cracks the carrier.
Mine was covered under warranty only because I was into the second year of the warranty which is now second party coverage and not Polaris and they covered it.
This is something you want to watch for when you bury your machine because I'm like every other polaris rider and want to show up my friends by going through the holes in 2 wheel drive

 

I have an 06 800 with 850 miles on it and have the problem with the AWD engageing by itself.
I changed the fluid and that helped some but it still does it.
I figured i would try the fluid before taking it to the dealer. Although its still under warranty , taking it back to the dealer is the last thing i want to do.

 

A little late on the draw but,.... I have had those bolts break 3 times. It is a very poor design, IMO. Many of the guys here shouted abuse! Anyway, thought I would chime in!