im sure its been asked before, i tried searching but came up with nothing
its a 2002 scrambler 400 4x4
4x4 comes on as it should when using the awd switch BUT
when spinning the rear tires rapidly the front will occassionally kick in.
Its horrible when it does, and ive been either keepin it in 4x4 or just not spinning much
any ideas? is this common?

i changed the 4x4 hub fluid, the stuff that came out was black. no improvement, this is a huge pain in the a$$ when having fun on ice or snow thanks in advance

 

Its normal because the polaris came out with something called the concentric drive system. its a feature for if you are in the mud sand or what ever you can slide in. Pritty much its so you dont get stuck. I dont like it because when I have my quad on the test stand it will auto enguage. but i have learned to live with it!

 

not its not normal. its designed to work on when the switch is on and the magnet in the hub activated.

You either have an electrical problem that is triggering the awd magnets in the hubs or you have a problem with your hilliard clutchs. DO all 4 wheels engage when this happens? If im not mistaken the 02 scrambler has the 4x4 hubs on the wheels so if both are engaging then i would guess its an electrical problem as mechanical failure of both hilliard clutches at the same time is very unlikely..

let me know if all 4 wheels engage or if its only 1 of the front wheels and we can help more from there.

It is not normal at all and you should fix the situation (leave it in 4x4 until its fixed) before you end up blowing your front differential or other driveline components from the shock of sudden engagement.

 

IT IS NOT NORMAL!!!!!!
go to the following site:

http://partsland.com/index.cgi?N=126...X4-FRONT-WHEEL

replace #4 on both wheels. anyone with a little bit of mechanical knowledge can do it.
Good Luck-PB500

 

Its only one wheel, and I no its not normal, the other scrambler did not do it, and I have it for parts, thanks

 

What is part #4 and its only one wheel kicking in, always front right,

 

ok one wheel makes it easier... 2 options.. take the entire strut assembly off (a arm, cv shaft strut and all and dont forget the coil wire) of the other machine or tear down your hub now and inspect it.

If you decide to take it apart you need to pay attention to the following...

the armature plate (#4 stated above), make sure it is flat. Make sure it is not magnetized(being magnetized without the coil will make it engage the hilliard clutch.)

The hilliard clutch, make sure the garter spring is tight and doesnt show signs of being worn out or stretching.. Spring needs to be installed with a special tool as to not stretch it too much if you decide to replace it (just use your parts hilliard already assembled)

Make sure the axle nut is not over-torqued.

make sure the correct amount of fluid is in there and its the right type...

verify that the coil is not somehow being energized when the switch is off (not likely but easy enough to rule out).

need to check clearance between the coil and sleeve seal that the armature plate rides against.

Actually... here is a good write up on the workings of a front hub...

 

Mine was the armature plates, as stated above, they were getting magnetized when in 2 wheel drive, causing my front right to engage. i stated to replace both due to the fact that if one is going out, i would strongly believe that the other is not far behind. might as well kill two birds with one stone and replace both. they are simple to do, allows you to inspect the hub, and makes you put fresh, new fluid in there. oh and they are really cheap. goodluck PB500

 

i think i'll take the assembly off the parts bike, just gotta wait for some time and motivation. Thanks very much guys,