I changed my hub fluid last night and found that the fluid in there was a dark brownish color. Pretty dirty stuff. What do all of you do to get the old fluid out? Also, is it possible to over fill it?

Thanks,
Jeff

 

sounds like you had water in them if it was brownish color. i do beleave you can fill it too much as i think the 4 oclock position is the right angle to fill to.

 

In my manual it says 7.5 CC of fluid in each (1999-2003).
When I first got my 2000 in 2003 I changed the fluid and there was nothing in the hubs (so I guess I added fluid), but the 4X4 worked fine. When I replaced te fluids I filled it up to the top, hub would engage and disengage at their will. I quickly drained that and put in the correct amount. I had a couple of rides where the hubs acted up, but now they are fine. I thought about taking the clutches and putting them in an ultra sonic cleaner, but they are working great now, so why :-)

Went riding a bit in the mud and snow and I can really tell that my 4X4 is working correctly.

Steve

 

I ACTUALLY CHANGE THE HUB FLUID EVERY MAINTAINANCE.PROBABLY EXCESSIVE BUT HELL IT TAKES ONLY A FEW MINUTES,ESPECIALLY IF I FIND ALITTLE GRIT ON THE MAGNET,I'M AMAZED THAT WEAK LOOKING SETUP WORKS AS SMOOTH,LONG AS IT DOES!TO FLUSH YOU CAN HALF FILL THE HUBS THEN DRIVE AROUND OR SPIN THE WHEEL ALOT THEN DRAIN+ REFILL.IF YOU DON'T WANT TO WASTE THE HUB FLUID YOU CAN USE TYPE F TRANS FLUID TO FLUSH,THE BOOK SAYS YOU CAN USE IT INSTEAD OF HUB FLUID BUT I FOUND THEY STICK ALITTLE, NOT BAD. HOPE THIS HELPS.

 

Thanks guys, I plan on doing this a couple more times as my right hub sticks and does not like to come out of AWD most of the time. The other thing I noticed was that when I had the front end jacked up, the right side was harder to turn by hand than the left. Also, as soon as you quit spinning the right hand side, the tire would stop while on the left hand side it would keep spinning if I quit touching it. Could there be a bad bearing in there? Or maybe the axle nut on too tight?

 

I flush out the old fluid with transmission fluid Type "F". Just fill it up and drain it out a couple of times,then put in the real Polaris hub fluid. You can flush it out with the Polaris stuff also but ATF is much cheaper.

I though of flushing it with brake cleaner or carb spray with its small red nozzle attachment up it the filler hole,but was not sure if that stuff was hard on seals or not.

 

VERY TOUCHY ON SPECS NO PLAY ALLOWABLE,CHECK YOUR SPEC.CAN'T BE TOO LOSE OR TOO TIGHT MINE IS 12FTLBS OR 108-144 INCH POUNDS. 01 SCRAMB 500 4X4.EXTREMELY IMPORTANT.THE ARMITURE PLATE ENGAGEMENT TO THE HILLIARD IS CRITICAL TO TORQUE SPEC.

 

I will check that this evening then when I get home from work!

 

I would have to agree with MECHANIKE, I am amazed at what acutally makes the AWD work on the 4th gen Sportsman, but I am so gald it works!

If I put mine up the fronts will turn in 2X4, but if you put your hand on them they stop. In AWD they all spin and you don't want to make them stop :-O

Steve