Hello Everyone!
I've recently noticed that my 95 Sportsman 4x4 AWD light does not stay lit for more than 10 secs after its pressed and my AWD did not work. I went to check the left hub and the fluid inside was jelled up and had a very obvious burned smell. I replaced the fluid then, but I checked it again today - About 4 months later and the fluid has the burned smell again. My AWD still does not work =( After taking the hub apart, I noticed the left outer magnet pole is ground down quite alot compared to the right which makes a big gap between the pole and armature plate when assembled, could this cause it? The clymer manual says its adjustable? Here are a few pics.

Thanks!

 

Its not the outer sleeve that you need to worry about! If the inner strut casting is ground down also,there is no repair for it but to replace strut. I've had several like this and have tried to save em,but with no luck. Awd just doesn't work properly! From your pictures really appears that inner pole is ground pretty flat! Check it against other side and you will probably see the difference! The inner pole is supposed to be pretty thin! I know you dont want to hear this,but I've seen plenty like it.

 

Thanks! I kind of figured I was screwed =(. I think I'm going to try and get a strut off ebay but does anyone know what years / models are compatable with a 95 Sportsman 400 4x4?

 

Not sure if this guy has what you need?? I just bought a couple A arms from him off a 95 sportsmans. Send him a message...he might have what you need?? I know he has other 95 stuff.

"brothersed" is his Ebay name.