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Old 06-18-2017, 06:18 PM
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Default 2004 Polaris Sportsman 500 HO 4x4

Should I use Polaris Demand Drive Fluid in the front hubs?
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Old 06-18-2017, 06:24 PM
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My two cents worth is yes Demand Drive Plus for hubs and centralized awd machines. Others have used Amsoil products among other brands which I suppose are good,but Polaris(better yet Lubetech that makes the oils for Polaris) has had years to perfect their awd fluid. Same way I recommend Agl for the gear case.
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Old 06-18-2017, 06:49 PM
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What id the difference between Demand Drive Fluid and Demand Drive Plus?
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Old 06-18-2017, 06:53 PM
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Thanks for the information. My 2004 Polaris Sportsman 500 HO 4x4 AWD will not disengage. I am going to take a close look at it tomorrow. Any suggestions would be appreciated.

I also had new rear axles put on a year ago. I noticed the the right side had come out of the diff. I put it back in but it came out again. What could cause this?
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Old 06-18-2017, 06:54 PM
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Plus was just the latest evolution of the oil that could be used in the hubs,centralized systems and also in the reservoirs of the adc type gear cases. The plus eliminated the adc oil and made one oil do all so there wouldn't be any confusion. Early models on the centralized diffs had problems on the plastic roll cages cracking and locking up the drive shafts. Aluminum replacement roller cages are available on ebay,amazon to solve this problem. On the drive shaft the circlip may be deformed and not locking into the groove good enough. Check a local dealer to see if they have a replacement or just order one if you have to.http://www.partzilla.com/parts/searc...AFT/parts.html Several videos on the roller cage and replacement.
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Old 06-18-2017, 07:22 PM
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Many thanks. I appreciate your help.
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Old 06-20-2017, 11:20 AM
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Default No magnetism

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Originally Posted by JB1313 View Post
Many thanks. I appreciate your help.
We pulled the front differential and the roller cage looks good. We put power on but the magnet did not work. We put on a new ground wire but still no success. Would this cause awd to stay on all the time?
Any suggestions?
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Old 06-20-2017, 11:34 AM
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Look close for hairline cracks in the roller cage.Plus check the armature plate itself for being magnetized that can cause lockups.If the output cover coil doesn't engage check resistance between the coil wires. Should be between 22-25 ohms resistance. When you get this sorted out I'd still replace the plastic roller cage since you're this far into it and as they all break sooner or later.
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Old 06-28-2017, 03:32 AM
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We found a hairline crack so replaced with metal roll cage. Checked the magnet and discovered a bad ground wire. We replaced the ground wire and everything seemed to be functioning. We reinstalled the differential and now have a few new issues.
1. AWD indicator on display no longer shows up.
2. Runs in 2wd until I engage AWD. Then will not disengage until I run in reverse for a few seconds.
Waht could be causing this?
Thanks
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Old 06-28-2017, 11:51 AM
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It's suppose to still run in 2 wheel drive mode even if you engage the awd switch. Awd engages only when the rear wheels slip then when they regain traction awd kicks out again into 2 wheel drive mode or it is supposed to.
Did you replace the armature plate when you replaced the cracked roll cage? If not that could be the reason for the lockup if the armature plate is magnetized. Backing up usually causes them to release. Same thing that would happen in the older hub activated awd systems. One side could stay engaged until you backed up and then went forward. As far as awd not showing on the display,is the gear position correctly showing on the speedo? If not could be the gear position switch on the transmission.If gear position is ok on the display,you may have to trace the wiring from the awd switch that leads to the speedo. The wiring diagram from the manual can help on that.2004 Polaris Sportsman 500 Service Manual PDF Download
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