Hello All,

I have strange problem,

I replaced one side of my ATV the Hub coil of the 4X4, becasue Accidentally I destroyed it when i replace the Ring of oil returns (I replace 2 two sides).

i push the 4X4 switch on , and the 4X4 not work,
i check the Voltage in the Hub coil, i got 12.8V, and the charging system i have 13.7V.

so i do some tests, i connected the hub coil directly to main wires, and i got 13.7V in the hub coil.

now, 1 from 5 times trying, only one wheel connected. so it 3X4 (not 4X4),
and some time is in right side, and some time is left side.

Test 2. i connected 15.5V from External power supply, and then i got the 4X4 Immediate.

every time that i start the 4X4 switch with 15.5V it work prfert.

and when i connectet the wires to the original system (12.8V) it does not work.

It is like the electric magnet too weak on 13.7V,

What your opinion ?


Thanks you all,
Mr. Tamir

 

Did you replace with a new hub strut sleeve also when you replace the coil? Plus clearance has to be .001 or flush all the way around, or awd will be erratic,plus did the inner pole of the strut assembly(that coil slips over) itself become nicked,damaged in anyway? If it has been worn or damaged can affect seating of the armature plate. 12.8 volts is sufficient for engagement and shouldn't have to take higher voltage to engage. Plus is hub torqued to 12 foot pounds? Too much or to little can affect the awd. Plus on a little different note is charging back to the battery while running between 14-14.5 volts? OPT

 

could be tranny switch thats bad, I find a hot wire under the front panel that gets hot with the key on ,then I run bothe red wires from the hubs to it and let the awd switch turn it on and off, has worked on several of the older machines.

 

Dear Friend,

you are very professiona, i didn't think about it at all.

I installed both sides new oil seal, and i didn't read the service manual.

now i can see the maximum alowed distance is 0-0.025mm, and i have 0.7-0.8mm distance,

maybe this is the reason why the electonic magnet is not strong enough for the 4x4 operation.

now i need to find a solution to get the oil seal (outer magnet pole) out.

Please look:








Polaris Hub Coils service manual

Thank you very much.

Respectfully yours
Mr. Tamir

 

This link seems helpful ATV Time :: View topic - Polaris Demand Drive Hub Q&A Picture Guide to Service

 

Thank you everyone,

You all give me good information.

Great forum.

Respectfully,

Mr. Tamir

 

Great post Astro Power. From my manual I couldn`t decipher witch part was the protruding piece. I ended up positioning the hub sleeve out further than the inner. It seems to be working flawless but seeing your post I am wondering if I have it wrong????

 

Hub sleeve should be flush with the inner pole of the strut(give or take .001) or armature plate will dish in over a period of time. You might be able to go around the sleeve with a mini torch (CAREFULLY) and FAST, just enough to expand the sleeve diameter slightly (without melting the coil wires!!),then take a small block of wood and tap inward,checking clearance as you go between outer and inner surface OR try to remove the sleeve without damaging the coil and reinstall (if sleeve isn't damaged) OR have another one handy like I sometimes had to do! OPT

 

I need to replace both front cv`s so while im in there I`ll bump out the hub sleeve`s. this will be my number 6 and 7 for cv joints since last September hehe for some reason it don`t like full stuff and WOT. I think I can now do the job with my eyes closed LOL Thanks OPT.