2005 sportsman 500HO awd kicks in sometimes when the switch is in the off position. Noticed it when i was in the mud. Can anyone help me out on this? I a fairly descent mechanic, just looking of a place to start.

 

Could be dirty or wrong fluid (or too much fluid) in the front gearcase or a cracked roller cage in there as well. Way too common problem to not be addressed by Polaris properly. It has been a problem since they switched away from the hubs at the wheels and went with the center "Hilliard" gearcase to control the AWD.

 

CURIOUS IF ANYONE HAS SEEN A CENTER HILLIARD, I WOULD THINK IT WOULD HAVE TO BE 4 TIMES BIGGER THAN A SINGLE WHEEL HUB HILLIARD TO BE STRONG ENOUGH.

 

It looks like a regular front gearcase.

 

It that plastic roller cages that can actually shatter if the front end engages while the back wheels are spinning fast. Another one of Polaris improvements for the worst,never heard of the problem with the hub old hub system.

 

i agree that its a weak point for sure but im guessing they put it in to be a breaking point instead of a whole front diff. there again i think most of the times they breakis because there being shifted into awd while the back wheels are spinning which is a sure way to break it in a heart beat. imo.