I have an 08 800 sportsman and my four drive was only working on occasion. I pulled the front hub apart and checked it all out. All looked good except oil was pretty bad, I put it back together with new seals and it now is very hard to turn by hand and seems as though it is always in four wheel drive now. Also I was wondering how I adjust the set screw where the magnet is

 

The 08 does not have the twin locking Hillary hubs, it would have the single locking Hillary in the front diff. (Centralized its called)

Not sure what hub fluid could of been in there. Should only be a straight foward wheel bearing all the AWD parts are in the front diff.

2004 was the last of the locking hub types, the Scrambler carried it on longer though.

Change the awd fliud (use the polaris stuff) in the front diff, if that does not work there notorious for a weak plastic roller cage breaking.

 

Do you know the John Deere part number for the armature plate

 

Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Item #15 ($52.93) is the armature plate for your model that you have listed,but if you're having problems,it may me more involved than just the plate?These models were bad on the plastic roll cages cracking also.

 

Thanks, I have it all ap[art and all loks great except the armature is warped or worn unevenly.

 

This has happened several times with me too over the years on these armature plates. You might as well go ahead and replace the plastic roll cage with a stronger one as they all eventually have problems. You can replace the roll cage with Polaris aluminum "high performance one" or with John Deere parts that other members have used. John Deere part #'s are courtesy of member Kerbbirds. http://forums.atvconnection.com/pola...r-rebuild.html

 

Okay, so i ordered the john deer part #MIA10656 and it looks the same but too small in diameter. Any thoghts on john deere part number. I have a 2008 800 Sportsman wit adc. I beleive the Polaris number is #3234407.

 

Had several people on the forum use the complete JD replacement parts setup. One member said it worked,but did take a little while to disengage at first. Don't know about who may have used just the JD armature plate instead of the Polaris plate. Hopefully if any have they'll give you some answers.