can u e-mail me direction on how to repair this? SAshton1@comcast.net

 

could cold weather also effect the front engaging. If its a plastic gage. I know plastic can be funny when it's cold so maybe cols weather effects it.

 

I know that they are suseptable to extreme vibrations created from "spinning" the rear tires. The new diffs have a different armature plate and a thust plate which helps to reduce this occurence. These have a coil which is electrified by the switch and thus magnified which engages the rollers and creates a mechanical lock in the diff. It is my understanding that the extreme vibration engages the diff by accident.

I think the new diffs with the thrust plates have a set screw which enables them to be fine tuned, or so I hope, ahich may help with the AWD engagement while in 2x4.

 

is the crappy plastic cage inside the wheel hub or inside the front diff?
How come Polaris do not remedy the problem if it happens so frequently?
Anyone got any idea what the cost of getting a polaris dealer to carry out the repairs would be?$1000?surely if they repair there would be some kind of warranty?

 

The plastic cage is inside the front diff.,04 and newer engages AWD in the diff.,being yours is an 03 I think it engages at the hubs. From what I was told, Polaris does not make the diff.,they get it from a company that makes them and Polaris puts them in already assembled.
I seems like they would try a different seat up with all the problems they are having with this one, this problem has turned alot of first time buyers off to buying one, and some from never buying another.

 

Being an 03 it is in the front diff. I have an 03 600 and am on my 3rd diff in 2300 miles. They know about the problem but nothing they can really do to fix it. The front diff used to have an aluminum roller cage but when that broke it would tear the whole diff apart. Now with the plastic cage when it breaks it just breaks to little peices and everything else is saved. They figure if under warranty it would be cheaper to just replace parts instead of the whole diff assembly. It is a known problem and it sucks that Polaris has done nothing about this. I love polaris but would never buy one again until they fix this problem. I now ride a 04 Honda rincon with 1400 trouble free miles. The sp just sits in the garage. Its a great system when it works but it only takes one time for it to engage under load then its junk. Once the cage gets stress cracks it will act up and eventually shatter.


Another one bites the dust.!

 

Where the AWD engages.

2002 and newer sp 700, in the diff. So all 600, 700, and 800 engage in the diff.

2003-and all sp 600 in the diff

2005-present sp 800 in the diff

2004 or 2003 and older 500s engage in the hubs.

2004.5 and newer 500s engage in the diff.

All scramblers in the hubs.

magnum RMK?

 

WOW. WHO SAID THE CAGE IS PLASTIC?

Very, Very funny. How can a solid steel axle be in any way near a plastic cage that engauges the AWD?


Whoever said that is nuts.

 

Dear Mr. SelfproclaimedPolarisAWDexpertwiththekawasakiname,

Why are you so concerned about what's being discussed in the POLARIS forum?

 

The cage dose not engage the AWD. It just holds the bearings that engage between like a cam.