i have seen 3 or 4 units in our shop with your same problem 4wd only works forwards. the cause was the plastic cage around the rollers broken. sorry but take it apart and see.

 

To Test AWD I use my ATV lift and lift the whole ATV up and flip the AWD switch and hit the gas, all four will spin as it thinks the rears are spinning. Should work for reverse.

Steve

 

Bikkat.

Well after going throught the whole wiring system , we ended up doing just that, I unplugged the diff wire and applied 12 volts to the coil while the bike was in the air.
Results where in forward the fronts spin and in reverse they don't.

So as colt2245p stated earlier I now agree that the cage is broke.

What really sucks is that I called the dealer and they want $260.00 for a new one!!!I thought what the crap is the dam thing made out of GOLD!!!.

Thanks to all the replyed.

Cliff

 

Check with ridgerunner--->ridgerunner.biz They have spt parts for extremely reduced prices on the parts that they don't use for their crawlers maybe they have a front diff or parts for less. Please let us know what you find because I for one would like to know how the cage or other broken part was damaged and still allowed AWD in fwd. Good luck.

 

Thanks for the info.

They have a waiting list for front diffs though,
I did talk to my dealer today and there was a correction on the parts prices.

Cage $280CND
Rollers $100CND
Complete diff $ 1000. CND

I don't know how these guys sleep at night.
I can tell you this, when I fix the diff she's going up for sale of trade.
I don't even really beat this bike and it seems to break alot of front end parts, and the problem is that there is no way of upgrading it to not break.

At least on my mud comp truck when I blow something apart I can always find something bigger and better to fix it.

I think there's a new 800 outlander in my future,Or something with with a 3-5 year warrenty.

Cliff

 

So is it the just the $280 cage that may need replacing or do the rollers require replacement as well? I can't believe it's so expensive. I'm pretty much stuck with this wheeler as it was a battle to get my wife to buy into getting one in the first place. Oh well, at least I can fix it myself an save the labor $$.....and of course I can prob justify a few new tool purchases as well.

 

The guy from polaris told me that if the roller where rusty at anytime then even if you cleaned them up and there in oil that the rust comes back and it will put stress on the cage, because it could cause a uncalled for ingagement, which twists the cage and breakes it.

My front diff was in really bad shape, I had replaced all bearings and seals, as well as the large bushing, but not the rollers.the polaris machanic suggested replacing the rollers as well.

So it looks like it will be $450.00 to fix this problem.

Those bombi warrenties are looking better every day.

Cliff

 

hmmm, well, after some searching I found the roller cage w/springs online for $183 and the roller kit for an additional $63. So using that source, looks like around $250 for the parts? babbittsonline with the w's and the dot com. Give er a try and see what ya think.

 

I was wondering if you adrenaltor or big country have disassembled your front diff to see what the actual problem was.

 

I haven't as of yet,hope to get to it this week.

bigcountryusa, thatnks for the link,with the CND doller as good as it is now it makes for a good deal.

Cliff