<div class="FTQUOTE"><begin quote>I'm used to an early 04 SP500. This central hilliard is new to me.</end quote></div>


I think 03 was the last year of the locking hub style for the 500 Sportsman.

 

Early 04 models of the singles (ie. 500) have the older hubs in the wheels, as well they have the old shifters. 04.5 have the straight shifters and the central hilliard.

 

I agree with the above. Check and change the fluid. I have on of my diffs out in the shed taken apart. I'll try to take some pics.

 

I had a machine in the shop the other day with the same problem. It had the central hilliard but I don't remember what year it was. Anyway he had put 80/90 in it in the summer and it worked ok. When it got cold the AWD would kick in by itself. I would try to put the right oil in it since the 80/90 is too thick for that model(non ADC model. Big thread by scrammytodd on front gearcases, search for it and read it, very informative.) I had both axles out on this particular unit so I went ahead and pulled the gearcase, disassembled, and washed it out. I would think flushing it would do the same thing.



scrammytodd's thread

http://forums.atvconnection.co...531542&highlight_key=y

 

Guys thanks for you help. I flushed it out and will continue to change the fluid frequently. But this hasn't helped the problem. It still comes on if I spin the rears. Not if I pull aways slow though. I'm starting to think it might be electrical? I'm not much of a mechanic, and the garage is not heated that I work in....so might just have to be carefull and live with it till the warmer weather comes.