The Polaris AWD Hub/Diff Thread
Dec 8, 2018 | 03:29 PM
#71
Weekend Warrior
Joined: Dec 2018
Posts: 1
Likes: 0
Polaris 700 stuck in AWD
I have an 03 Polaris 700 sportsman stuck in AWD. Took the front differential off and checked everything inside and all seemed clean and good. Put it all back together and it seem like it was fixed because everything operating independently. I wanted to put a charge to the electromagnet to see if it was going to engage the tumblers and then disengaged when I took the charge off. Put a 9V on it and it engaged the magnet, but unfortunately when I took the charge off, it doesn’t completely disengage and went back to what it was doing before. I’m guessing that something and the unit has become magnetized and won’t allow it to release completely. I did notice it when I took it apart originally, the electromagnet had a slight magnetic charge to it to where it would actually hold a paperclip, but I wouldn’t think that would cause such an
issue. Any suggestions? Is there a way to demagnetize it because when I took it all apart and put it back together, it was perfect.
issue. Any suggestions? Is there a way to demagnetize it because when I took it all apart and put it back together, it was perfect.
Jan 9, 2021 | 10:56 AM
#72
Weekend Warrior
Joined: Jan 2021
Posts: 1
Likes: 0
Polaris Sportsman 500 h.o. 2007
I have a problem with AWD. It kicks in even though there is no power ( the cable is disconnected at the moment). Everything was checked: the plastic cage exchanged, the rollers, too. I also checked the armature plate if it was magnetized, but it wasn't. The fluid is new. I'm desperate at the moment, I have no idea what else can cause AWD kick in. Any advice?
Aug 18, 2021 | 10:57 AM
#73
Weekend Warrior
Joined: Aug 2021
Posts: 2
Likes: 0
(Admin please pin this to keep down the recent amount of AWD topics)
I am here to explain how the AWD in a Polaris works. I ave worked on them for years and know exactly how they work, and the symptoms on how you can tell when they are going bad. I will also teach you how to avoid having costly repairs on them. Any questions or concerns about your Polaris AWD system, post them here, we will be happy to fix your machine.
Polaris uses a combination of electro-manetic power, and mechanical systems to give you 4x4. I for one am happy with my Polaris AWD. This is how it works:
For some of you out there, your AWD will not work unless the button is on. [img]i/expressions/face-icon-small-smile.gif[/img]
Your back wheels must spin a 1/5 before your AWD even kicks in. Once your back wheels spin a 1/5 out of sync with the front, the axle inside your hub/differential still tries to spin, and a cage holding a set of "rollers" expands everytime the axle rubs against it correctly. (If you have a older Polaris, try taking apart your hub and try it yourself up on jack stands) (older models-->[img]i/expressions/face-icon-small-wink.gif[/img]The cage is held their by a electromagnetic coil that is located inside your strut tower. When you press that AWD button, that electromagnetic coil holds the armature tight against the inner part of the strut tower. The armature plate has 3 little ears on it that slip inside the cage, which it already has grooves cut inside of it that allow this to mesh together. It will create enough drag to allow the cage to stay still while the axle pushes these rollers out and allows it to catch on the inner part of the hub.
Once they are back in sync, the axle no longer has to mesh with the cage any longer because the front wheel is already spinning. The only downside to having this AWD setup is that its not reliable ( i will explain this later on) and it will take a few minutes for the front wheels to catch up with the back when your pulling a long stretch hill.
Hey, I love the Polaris AWD, but you know what, Its not always reliable. I have had some many stories told to me about their Polaris AWD systems. Those cages can only take so much rubbing back and forth. Some guys wheel would kick out right in the middle of a large mud puddle and just randomly stop working. Or, it will continuosly stay engaged! (Which makes it extremely hard to steer correctly) Sometimes you can free this up by putting your quad in reverse, moving a few feet and pressing the override button a few times then going forward again. But buddy, you will know when this is locked in for good.
I personally prefer the Kawasaki design.. It has a limited slip differential, which you can have easy steering in 4x4, but if you need all 4 wheels locked in you pull a yellow handle and your locked in solid.
Now, to avoid these Polaris AWD problems there are very simple things you can do!
1. Change your hub oil between every 3-7 months depending on how hard you ride your Polaris.
2. When your not using 4x4, dont have the button on! (Simple and effective. Think about it)
3. Always keep Fresh Hub Oil (Green Labeled Bottle) inside your hubs when you go on long rides.
These are just some of the methods of keeping your 4x4 system working for a long time.
Just remember, Any questions on your AWD, please post them all here so the forums stay clear of all the recent posts.
Thanks! [img]i/expressions/face-icon-small-smile.gif[/img]
I am here to explain how the AWD in a Polaris works. I ave worked on them for years and know exactly how they work, and the symptoms on how you can tell when they are going bad. I will also teach you how to avoid having costly repairs on them. Any questions or concerns about your Polaris AWD system, post them here, we will be happy to fix your machine.
Polaris uses a combination of electro-manetic power, and mechanical systems to give you 4x4. I for one am happy with my Polaris AWD. This is how it works:
For some of you out there, your AWD will not work unless the button is on. [img]i/expressions/face-icon-small-smile.gif[/img]
Your back wheels must spin a 1/5 before your AWD even kicks in. Once your back wheels spin a 1/5 out of sync with the front, the axle inside your hub/differential still tries to spin, and a cage holding a set of "rollers" expands everytime the axle rubs against it correctly. (If you have a older Polaris, try taking apart your hub and try it yourself up on jack stands) (older models-->[img]i/expressions/face-icon-small-wink.gif[/img]The cage is held their by a electromagnetic coil that is located inside your strut tower. When you press that AWD button, that electromagnetic coil holds the armature tight against the inner part of the strut tower. The armature plate has 3 little ears on it that slip inside the cage, which it already has grooves cut inside of it that allow this to mesh together. It will create enough drag to allow the cage to stay still while the axle pushes these rollers out and allows it to catch on the inner part of the hub.
Once they are back in sync, the axle no longer has to mesh with the cage any longer because the front wheel is already spinning. The only downside to having this AWD setup is that its not reliable ( i will explain this later on) and it will take a few minutes for the front wheels to catch up with the back when your pulling a long stretch hill.
Hey, I love the Polaris AWD, but you know what, Its not always reliable. I have had some many stories told to me about their Polaris AWD systems. Those cages can only take so much rubbing back and forth. Some guys wheel would kick out right in the middle of a large mud puddle and just randomly stop working. Or, it will continuosly stay engaged! (Which makes it extremely hard to steer correctly) Sometimes you can free this up by putting your quad in reverse, moving a few feet and pressing the override button a few times then going forward again. But buddy, you will know when this is locked in for good.
I personally prefer the Kawasaki design.. It has a limited slip differential, which you can have easy steering in 4x4, but if you need all 4 wheels locked in you pull a yellow handle and your locked in solid.
Now, to avoid these Polaris AWD problems there are very simple things you can do!
1. Change your hub oil between every 3-7 months depending on how hard you ride your Polaris.
2. When your not using 4x4, dont have the button on! (Simple and effective. Think about it)
3. Always keep Fresh Hub Oil (Green Labeled Bottle) inside your hubs when you go on long rides.
These are just some of the methods of keeping your 4x4 system working for a long time.
Just remember, Any questions on your AWD, please post them all here so the forums stay clear of all the recent posts.
Thanks! [img]i/expressions/face-icon-small-smile.gif[/img]
Apr 28, 2025 | 05:21 PM
#74
Weekend Warrior
Joined: Apr 2025
Posts: 1
Likes: 0
tried everything and awd hubs no engaging???
i replaced everything and still couldn't get my hubs to engage. worked on this problem for a couple of years. just as i was about to pull out my last strand of hair i had a epiphany!!! Deglaze the inside of the hubs???? i took a sandpaper/Scotchbrite drum on my drill and scuffed up the inside of my hubs..... bingo!!!!!! hubs engage almost instantly!!! i know this will help someone 😁👍
Hi I have a 2000 Polaris 500 scrambler 4x4 and this is my other problem. The hubs will not engage. I have had them apart a bought 10 times and everything looks good in regarding to the manual. I just can’t find out what the Holmes of the magnet coils should be in my manual? Is it possible that the rings that grab on the magnets are holding residual magnetism? And not grabbing as strongly as they need to? I am as a loss with this one I think.
Thread
Thread Starter
Forum
Replies
Last Post
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)