If the rev limiter black wire is disconnected, the All Wheel Drive is engaged all the time right? Even if the AWD switch is turned off? And when the All Wheel drive is turned on, do the front hubs engage immediately, or do they engage gradually with the speed of the rear axle? It would be cool if there was a company around that made manual locking hubs for these. So the could be manually locked in by hand. Instead having to rely completely on electronics to activate the front hub assembly's. I'm eventually going to rebuild the front hubs
on my Sportsman 500. But not right now, dont have enough $.

 

not sure on that year but...no, if u disconnect the rev limiter all it does is allow you to not have to push the button, everything else should work like normal otherwise...awd should only work when it is switched on..

 

and when awd drive is on, the front tires should only kick in when the rear tires break loose..i could be wrong tho as im not sure on that year

 

Nope.. Disconnecting the reverse limiter just bypasses the limiter module so you don't have to push the over ride button in reverse to get full power. The over ride may still have to be pushed in reverse to allow awd on some models. This module has nothing to do with forward range and awd action. Front wheels engage when the rear wheels slip,loose traction. Usually happens very quickly,about 1/8 revolution slip of the rear wheels whether it's in forward or reverse. The system in not a full time 4 wheel drive,but designed to kick in and out as the terrain allows. That's why it's called an electro/mechanical awd system. A ramp in the roll cage ramps bearings up and locks into the inner part of the hub when the front tires are turning slower then the drive shaft. Again this happens when the rear wheel slip and this causes the drive shafts to speed up. This action is partially because of the drag on the hilliard by the armature plate. The armature plate(hooked to the hilliard by 3 tabs) is slowed down by magnetic pull from the strut coils. If you do anything to this system,just wait until you have enough $ to fix it right the way it was was designed to operate. Too many parts involved to try to rig things up without damaging other parts even further. Look at this video. Can give you a better idea on what parts are involved.
And yes I've had guys that have come into the shop that have actually had roll cages mounted in the hubs,ramped them up and tack welded them in the locked position.. They weren't rewarded for their efforts very long as they wouldn't hold up. I've seen people try to rig front wheels up that there was no way I'd ever get on one.

 

Thanks for the reply's guys. OPT your explanation how the front hubs work, helped a lot. I'm going to save my $ and go through both hub assemblys. Right now the left front hub seal is slowly leaking fluid out the back. So that one will definitely have to be taken off and fixed eventually. I thought as soon as the AWD switch is turned on, the front hubs were immediately both "locked" in, even if the 4 wheeler is sitting still. Now I understand more how they function. Before I read your replys, I thought for some reason that disconnecting the black wire on the rev limiter activated the AWD full time, even with the AWD switch turned off. But now I know better . Thanks again guys.

 

So does my 2011 Polaris Sportsman 400 HO have a rev limiter in high and low? Because i cant tell if it does or not. thanks

 

The rev limiter is only supposed to kick in when you're in reverse. The yellow button is the override for it.

 

Reverse over ride limiter module. And no yours is incorporated into the speedo,not a separate module like in the older models.You do have "rev" or rpm limiter but that's built into the cdi.

 

if you go about 88 mph and hit that button...you will travel time

 

So there is an rpm limiter so i won't blow up my machine in forward gears? When I am in low going full throttle in the mud or on the trail, rpms really high, it doesn't seem to have a limiter at all.