I have replaced Throttle control (awd switch) replaced coil on left front wheel, replaced fliud recently, cleaned all electrical connections, replaced joints in Shaft.
Have 13. 2 volts going to front coils. all wheel drive wll not engage. Anybody have any thoughs
Thanks

 

Hub seal sleeve correct distance from the inner pole? If not magnetic pull may not be enough to grab the armature plate on the sleeve face and inner pole. Plus 12 pounds torque on the hub nut? Did you hold the drive shaft steady as you pushed the hub back on? Have had several people just push the hubs back on which just caused the drive shaft to move rearwards a little and the armature plate slipped out of the hilliard slots.

 

Ok, I have parts manual, but to be sure I understand, the Hub seal sleeve you are referencing is item that covers the coil and rear hub seal contacts? Thinking I tapped sleeve on as far as it word go. I am sure the armature plate is in the correct position, as for the hub nut i believe i tightened nut down than backed off till Hub rotated easily. I will try tightening to 12 ft lbs.
2 things i forgot to mention on originaal post. reason I replaced Throttle control was the AWD switch appeared to have shorted out and melted in location of AWD switch and after replacing , indicator lite does not work on new unit. (Switch in ON position 13.2 volts to Coils, Switch in OFF Position 0 Volts to Coil) Applied 12 volts to coil and it energized. Does this info change your diagnosis ?
Thanks for info
Richey

 

Parts manual won't do the job of a good service manual especially on hub work. You need a good service manual as the hub seal sleeve doesn't bottom out on the strut and the hub nut isn't like a car axle nut that you tighten and back off until it rolls ok. Here's one that can solve most of your problems.2004 Polaris Scrambler 500 Service Manual PDF Download