O.K., I put the atv on blocks, cleaned the 4wd button, fired her up and put it in 4wd. All four wheels turn, the front ones with some pull. Hit the button again, and they stop. Put the atv on the ground, and I only have 2wd most of the time and sometimes it kicks into 3 wd. I removed the hub cover and outer wheel bearing, and no fluid came out. I sprayed brakleen in there, then buttoned it up and filled it with tranny fluid. Tried 4wd again, and still does not work!! Could the clutches be shot?

 

Welcome! If you used AGL gear case oil instead of Demand Drive hub fluid,could be the problem. Also the hub was dry for a reason! Either it hadn't been checked/changed in awhile or you have a hub seal or strut seal leaking or both. Try fresh hub fluid first. If doesn't help you may have to check the inside of the hubs at the bearings,armature plate,coil,hilliard assy,etc.Look for any oily residue around the inside of the hub and the back side of the strut. You can also place the atv against a post and see if the front tires spin after you do a fluid change. Also the back tires have to slip before the front tires will kick in. OPT

 

I will check what you described, Thanks for taking the time to respond

 

old polaris tech,
I changed fluid, but still not go. I removed the hub and bearings. There is a plate on the inside of the clutch with ears on it. All is intact. The coil that is goes up against appears scored on the outside edge. Does this part have a seal attached to it? Could it be that this coil is bad? Can I test it somehow without taking it off the machine?
thanks

 

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This shows the strut hub seal sleeve and the coil. If the seal sleeve is ground down,replace it and the armature plate.IF the inner part or "inner pole" of the strut itself where the coil mounts is damaged/ground down,the strut must be replaced!! You can check if the coil is ok by having it in gear,key switch on,hold the armature plate close to the coil,then push the awd switch. The 3 tab plate (armature plate) should pull towards the coil and sleeve and hold firm. When the switch is released, the plate should be easy to move. OPT

 

Hmmmm ... I'm going to have to think about that one.

 

I checked the hubs on both sides. Coils seem to work by grabbing plate when switch is on and not when switch is off. Put it back on the ground, took it out and now the intermittent 4wd is on the opposite front wheel. But still only goes into 4wd all the way whenever it wants to. Could there be something wrong with wear each shaft goes int the final?

 

Any time you go into the hubs replace the armature plates! This could be the source of the problem of intermittent awd if they are worn/partially magnetized.Most do after a few years. The hub nut torques to 12 foot pounds only also. OPT

 

change armture plate and make sure there adjusted correctly...some seem to over tork when they reinstall the wheel.. Strut Sleeve to the inner ring (magnet). Supposed to be .000 to .001 inch clearance with the "gap" on the inner ring.$10 armature plate from bikebandit.com...