I'm still waiting to get my manual through ebay but while waiting I have been going through the 99 500Magnum I just bought and every once and a while when I use the AWD then go to dis-engage it the machine will pull real hard to the left OR the front left tire will still spin as it would if engaged, if I put the ATV in reverse and burp the gas a bit then it will dis-engage - it acts like the old automotive 4 wheel drive systems. From what I can see/tell I have the AWD auto hub style system not the front diff. style, anyhow is this a common problem? Is there something in particular I should look for or should I just take it apart and clean it and put fresh diff. lube in-while of course looking for any broken parts? What should I use for lube? Are there any known common things I should look for? Whats the proper usage for Polaris's AWD system? Ive had the system explained pretty well to me here in the forum but not the proper usage. I know these questions are a pain in the ..... but I want to know the correct use of the system, not some cowboy backyard theory's. Thanks for your patience with all my questions guys, you've all been very helpful with little razzing so far and it is appreciated.---MaineWheeler

 

My Scrambler had the same problem last year, I replaced the garter spring. It is the circular spring that hold the rollers in place. This fixed my problem. I hope this helps
Cory

 

I WAS USING TYPE F TRANS FLUID CAUSE THE MANUAL SAID SO+ I WOULD EXPERIANCE NO UNLOCKING RIGHT AWAY,REPLACED IT WITH ON DEMAND FLUID+IT NEVER HAPPENED AGAIN+THAT WAS 75 MILES AGO.MAKE SURE THERE IS NO PLAY ON YOUR WHEELS.

 

How do I check the Garter Springs to tell of they are worn? Jack one front wheel up at a time grab hold of tire and?? Check it as I would a automotive wheel bearing or with a In&Out motion? I ask this because from looking at the parts diagram it looks as if the only purpose of it is to hold the rollers in their cage slots so I am not sure how to check them even if I took the hub apart other then if one broken. But where its just the one side only that does it, I'm sure its got to be inside that one hub assembly ------- Also this "On Demand" fluid is it a Polaris Dealer item only? And where are you talking about using it? the transfer case or the front differential? --

 

Fluid is in the hubs themselves. garter springs help the rollers release the hub.

 

I am not really sure how to "test" the garter spring but it is a cheap part and worth a shot.

 

You will see a little Allen screw at each hub. Take them out and drain the fluid at 6 O'Clock. Refill with the Polaris stuff through same hole,put hole at 4 0clock position until fluid drains and reinstall Allen screws.

 

<div class="FTQUOTE"><begin quote>Originally posted by: TLC

You will see a little Allen screw at each hub. Take them out and drain the fluid at 6 O'Clock. Refill with the Polaris stuff through same hole,put hole at 4 0clock position until fluid drains and reinstall Allen screws.</end quote></div>


I have a 2000 500 Mag, basically the same set up. The service manual I have says the same about the 4o'clock position but shows 10o'clock in the pic. Does the hub require such a small amount of fluid that it is filled at the 4o'clock position? I am curious about all this as well I am having some of the same problems.

 

It does to take much fliud and a over fill Will cause it not to work right also.

 

Drain the fluid in the hubs, refill, run the machine for a few 10-15 minutes. Drain it again and refill. Don't overfill. Mine were acting up as well, I had drain them 3 times, the fluid kept coming out dirty after a 10 minute run. After the last time it was clean and my hubs engaged quickly and smoothly, also disengaed smoothly. Cheap and easy to do this. It may not be your problem but worth a shot, it worked for me.