Hi Gang,
My 2001 Polaris Sportsman 500HO is having an issue.
The left front wheel does not engage into 4x4. The right front wheel works just fine. The left hub will engage some if I got the RPM's really high.
The connections that run from the magnetic coil to up under the "hood" to the connections there (hope that explaines where I am). There is 2 of them there, 1 for the left hub and 1 for the right hub. If I switch them around the right hub will work eaither way, but the left will not. This tell me that the problem is lower down the wire towards the magnetic coil or even farther.
The clutch is working fine when tested by hand. There is an adjust that can be done of outer to the inner pole, by moving the outer pole. If i find that when I measure this gap and it needs adjustement, could this be what the problem is? Or more clearly of a question.... Can this "gap' being incorrect cause the problem I'm having?
I'm going to check the wiring to make sure there is not a bad spot between the connecion and the magnetic coil also.
The fluids are fine and correct.


Stuck in 3.2 X 4 in Kansas,
John

 

If you swapped wires and it stayed on the same side I am guessing electrical is OK and your problem is mechanical. Pull off your hub and check the one way clutch on the axle. That would be my first place to try. Where in Kansas are you? TORK.

 

I'm in Ottawa.
I tested the clutch and it seems fine. The repair manual mentions an adjustment of the inner and outer poles, what does this adjusment do and if the setting of the adjustmnet is off what does it do?

 

If even one tire is spinning, the electrical is working. Pull your front diff apart and check to see if everything is good, chances are that sliding plate is not sliding, i had the same problem and all it needed was a good cleaning. Be carefull of the bearings, they can be a bugger to put back in.

 

I fixed the 4x4 drive. I just tapped the sleeve seal inward with a rubber mallet and got the gap between the inner and outter poles into specs. It works perfect now.