Hi,

I have a 1995 Polaris D-BAT, the one with the Yanmar diesel engine. It's a great tool for running round the farm, not fast but so much power that it will climb up the side of a barn if you ask it to.

Anyway, I've been trying to find out why the 4WD isn't working. From what I have found so far, the chassis is apparently a early/mid-90's Magnum/Big Boss chassis and so I bought the only Haynes manual that came close, i.e. the one that covers all models (except diesels) from 1985 to 1997.

Unfortunately there is nothing in there at all about how the 4WD system works, it mentions it in passing but gives no other details.

As it is operated by a switch on the handlebars, I am assuming there is some kind of electrically operated clutch in there some where, does anybody have any info or can point me in the right direction please ?

I would expect that it will be very similar to any mid-90's Polaris 4WD system so any info no matter how general might be useful. Is there a better manual I can buy ?

Also, any idea where the chassis/frame number might be, as then I can definitely identify what chassis it uses ?

Thanks in anticipation for your help,
Brian (UK based)

 

you need to see if the switch(awd button) has powewr going thru it and the bulb is lightiong up and not blown. then the power goes to the hubs to power the coils. start w/ tracing power first. someone w/ better knowleadge might have better ideas but its a start.

 

jack the entire 4 wheeler off the ground. turn the rear wheels forward. the front 2 drive shafts should be turning. check for 12 volts at the electro hubs. (each hub should have its own 2 wires). if 12 volts are thare with key on then check coil resistance. if coils check out good then start disasembling front hubs. inside is a clutch mechanism (hillard) that may be broken. hope this helps

 

try this

http://pi54.com/corp/manuals/Parts/9914915r01.pdf

 

maybe as simple as the fluid level in the hubs. good luck

 

Low fluid or wear caused by low fluid. It happens too often when people don't check it.

I believe most of the non-engine parts would be the same as a Sportsman 500 from the same period. Parts should be available. You can cross reference them here. http://parts.polarisind.com/Browse/Browse.asp

 

Thanks for your help so far folks, the link to the manual was really useful and the name of the clutch (hillard) let me do a search that came up with a great functional description of the AWD system on this very forum so at least I now know how it's all meant to work.

So far I have confirmed I have power to the switch, and the light on the dash comes on and off. I haven't checked the front hubs yet. Quite a clever system really, just a shame it drives all of the front powertrain as far as the hubs all of the time whether drive is needed or not.

One thing I can't locate is the type of oil to put in the front hubs. The owners manual states "Premium Hub Lube", is there a generic name for this, is it EP80 or EP90 or something like that ?

Thanks again for all your help, Brian

 

the generic fluid on the older models would be automatic transmission fluid (ATF)type "F" filled to either the 3 or 9 oclock position on the fill hole...

 

Hi , I've already boughe one of this kind of ATV . Can you help me with some informations about the engine . I must find out , soonest I can , how many oil liters goes in the engine ! Please help me !

 

We only sold about 3 of these machines and only had one come back in for minor problems. You're best bet is to get a manual. They're not cheap because they weren't made that long.http://www.ebay.com/itm/2000-Polaris-Diesel-series-10-ATV-Service-Manual-/150512710378?pt=Motors_Manuals_Literature&hash=item230b41b2ea&vxp=mtr