About 2 weeks ago I noticed that my 2006 800 was kicking into 4 wheel drive when the switch was in 2 wd. I took it back to the dealer and they said they would try to get it fixed under warranty (just ran out at the beginning of the month). Well, I picked it up today and the service guy that worked on it said he pulled it apart and everything looked fine so he put it back together, and it was still doing it. When he called polaris they said "oh you need the upgrade thats avaiable". He said that the upgrade he put in looked exactly the same as what was in it to begin with. Has anybody else heard of this? I'm not sure exactly what part was "upgraded" either. Whatever it was it fixed it. I still had to pay the labor for it to be done, they paid for the parts.

 

I was curious about your thread?I was told when I bought mine that the 05?s had this issue. I was told that parts inside were getting magnetized and this was causing the AWD to kick in 2WD mode. From the parts list on the Polaris site it seems that there were changes after 06/13/05. The changes aren?t broken down just an assembly # Looking at the 06 parts list they added a Thrust Button and Thrust Plate (Items 3&4) just inside the outer cover?? Whether this was the fix or not?. The other notable difference is the Clutch housing/ Ring gear and clutch . It looks the same but has a different Part #


The 07 front diff was completely changed

Totun

 

Update:

The thrust washer and Thrust Plate are to adjust gear back-lash. Not sure why it isn't in the 05 version.

Do you know what parts changed even though they looked the same.

Totun

 

I'm not sure what the part was that he replaced. Has anybody else heard of this upgrade?

 

I have an 05 800 and have not had this problem yet. Would it be possible for you to call the mechanic you spoke to at the dealer that did your work and ask him specifically what parts are in this "upgrade" and report back to us. I have not heard of this and I think we would all be interested to know what the replacement parts entail.

 

imy 06 hasnt had any issues w/65 miles and i also havent heard of an up grade. i dont beleave its ever been mentioned on here.

 

I was looking on the internet last night and i found on the one website that the one part replaces another. I'm guessing that this is what he replaced on mine.


Diagram

 

The cage for the rollers is made from a different plastic and the armature plate design was changed.