2004 Polaris Sportsman 500 problem
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2004 Polaris Sportsman 500 problem
I had this problem with my 06 800 sportsman, for awhile I could back it up 20 feet or so and it would disengage. I thought it was a u-joint or the front axles. Took it to the dealer and surprise, after first couple of words they knew the problem. I don't know the name of the part, but it is in the front gear box, the roller bearing was broke (don't quote me on that name) It seems that Polaris in all thier wisdom decide the bearings should be encased in plastic instead of metal. The part was over $200, and the labor was covered under extended warrenty. Problem solved
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2004 Polaris Sportsman 500 problem
w/out pulling it apart there is no way of telling if its the cage for sure, but you know its in the internal front end anyways since theres no hubs to mess up. some have run a john deere part to replace the polaris/hillard parts as there way cheaper. do a search on here for roller cage/front end issues and you'll find all kind of info.
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2004 Polaris Sportsman 500 problem
You would think if it was the "notorious exploding Plastic roller cage" problem that the AWD would not work at all,or be stuck in True AWD and would be uncontrollable to steer like a ATV in Diff lock is.
The only reason a Polaris in AWD can be steered is because it goes back into 2wd the instant the rear wheel do not slip. If it was stuck in AWD 100% of the time there would be no way to steer the front wheels on soild ground if they stayed lock up in drive.
The only reason a Polaris in AWD can be steered is because it goes back into 2wd the instant the rear wheel do not slip. If it was stuck in AWD 100% of the time there would be no way to steer the front wheels on soild ground if they stayed lock up in drive.