Hi guy's, i have a 99 Xplor and last weekend my AWD light would take some time to light up when i put it in 4x4.Also while doing some donuts in 2 wheel drive the front wheels engaged !!!!.BANG I thought the whole front end broke in half.But after a quick check the front end looked ok.I had 2 run it in 4x4 a day so it would not happen again.Has this ever happened to anyone,its the first time that it ever happened to me. Thanks

 

Steve it might be that the gear oil in the hubs has leaked out, or gone sticky due to contaminants, this might make the outside race of the clutch in the hub engage without the AWD button on. You should probably take them apart, clean them up and put in fresh gear oil(I think they just use regular gear oil). The seals may also need to be replaced.As for the AWD light, wiggle the shifter and see if it flickers,I think they are bad for wearing out.I know it isn't much but I hope this helps a little!

 

its common. i call it polaris 4x4 syndrome! take your front hubs apart clean everything real good put it together and put fresh POLARIS HUB OIL in it. it should be fine unless you messed up a shaft when it engaged on you

 

Forgot to say that i had drained and flushed the hubs a week ago and put in automatic tranmission oil in it as i've always done.While i was there i took off the hub caps and loosened up the axle nuts a little bit(found they were a little tight).On my 93 and 98 polaris i've never had that problem and out of most of the polaris's around here only my friends scrambler has engaged at full trottle which cost quite a few bucks.I've got a big ride planned for friday and would really like to fix it before.Having to spend the night in 4 wheel drive sounds boring.Might as well get a Honda lol

 

The hubs will lock erratically/unreliably if the axle nut isn't tightened properly.
It also helps if you use synthetic ATF as opposed to the regular.

The newer machines won't engage the 4wd above a certain speed/engine RPM. If you flip the switch, it will 'wait' until it slows down. I imagine it is so someone doesn't lock it in wide open.

 

I know the torque setting for the hubs is high so re-tighten them and as mentioned use the correct synthetic hub oil.
Matt
2000 500 Scrambler.

 

Steve, Iwas talking to a buddy, asking him about the hubs cause he had the same problem.I find it hard to believe but he replaced the plates behind the hub..they look like a washer with tabs that fit into the backside of the sprag cluth.Apparently the dealer claims that it doesn't take much wear for them to cause this,,,I dunno myself but the guy that did it says it cured the problem,,the plates are only a couple of dollars so it might be worth a try

 

Thanks guys, i have to get some tie rod ends friday so i might as well get some plates too.Hope it will solve the problem.Does anyone know the torque specs on the axle nuts ?