1999 Polaris Xplorer 400- 3wd....
 

Hey all,
New to this block so still learning the ropes.
So I have a 99 Xplorer with the 2 croaker in it, and it was given to me by a friend. Not much known about it. Probably run hard but not boggin in mud, just farm use.
Anyway, I changed the hub fluid with ATF before i tried the AWD. My speedo isn't working, so I modded the system by bypassing the speedo and shift lever, so anywhere i want awd i move the switch and i know i have power to the electric coils.
The LF has always engaged properly, reverse and forward. The RF never engages, either direction. I have been trying to figure out the whole stupid clutch junk. to me kawasaki and arctic cat have done the best way. Anyway, how is the best way to tear into these hubs? I have ohmed the coils and they are both at 25. Voltage is good when i slide the switch. I can get an armerture plate for around 12 bucks, polaris oem. Is that a safe bet if it is warped at all?? What else do I need to look for??

Also wanted to add that the rest of the bike runs good, already did a little mod to the airbox and that helped a lot. Premixing my own gas. Was surprised at how much torque this makes for a 2 stroker!

Armature plates are the main wear item in the hubs,but for the most part they become magnetized and lock hubs in when not expected or needed or even in 2 wheel drive mode. Yes the plates can also warp causing the awd not to function properly also. If mine I'd replace both plates as more than likely wouldn't be long before the other side does the same. Even if you're getting voltage to the coil and the coil ohms out correctly,you might check the clearance between the hub seal sleeve and the strut inner pole also as they need to be flush with each other or no more than .001 gap between them. The surfaces need to be smooth and not ground down also. You can use ATF but the Demand Drive Plus is a better fluid for the hubs. Polaris quit using ATF years ago,but some of the old manuals still list it.Hub nut torque is critical also. No more than 12 foot pounds,but usually around 10 foot pounds if you have to back off the nut a tad to align the cotter pin holes. Some good videos out there to help you on hub service/repair but a good manual goes into better detail. Here's a cheap manual if you need one.http://polaris-atv.brssm.com/1999-Po...ce-Manual.html

Ok so between the hub seal and hub tuere should be basically no space? I read that somewhere and havent checked it out. I have yet to pull it apart and i think it will be easier to visualize what is going on in there once i get it apart.

Yes they should be flush with each other or no more than .01 between the sleeve and the inner pole of the strut.There will be two wear rings on the back of the armature plate where they rub against the hub sleeve and inner pole.This is normal,but check the plate for warping or any rough wear on the face of the hub sleeve or inner pole. You can test the pull of the armature plate to the sleeve. With awd on the plate should be holding firm,somewhat hard to remove.If the armature plate wear rings are really deep or plate is warped,it needs to be replaced.

So the wear rings are seperaate from the plate?

This is a plate that needs to be replaced..

So, pulled apart the hub today, wasn't as hard as I thought it would be. First observation, the spindle nut was hand tight, if that. Floppy loose after after I had pulled off the cover. The cotter pin was still there, but it was pretty loose. Could that be a sign for bad bearings?? I wouldn't doubt if they were. After that I pulled out the clutch assembly, followed by the plate. It was bent BAD!!! I did see the 2 wear rings you mentioned, not worn bad or deep but the plate was bent bad.https://cimg6.ibsrv.net/gimg/atvconn...75bf395130.jpgBent plate!
https://cimg9.ibsrv.net/gimg/atvconn...33f4f90d26.jpgCorrect orientation?
https://cimg0.ibsrv.net/gimg/atvconn...8f25e02e83.jpgAssembly with clutch

I found an armature plate on Amazon for 10 bucks, the brand was a Caltric- never heard of them but looks like a round piece of metal to me https://atvconnection.com/forums/ima...ons/icon10.gif

So I pulled apart the hub today and found 2 things- one being a hand tight spindle nut, the other being a badly bent armature plate. So to the store I go! Have 2 things hindering the engagement so hopefully one of them will be the cause. https://atvconnection.com/forums/images/icons/icon3.gifhttps://cimg5.ibsrv.net/gimg/atvconn...06319e6828.jpg
https://cimg9.ibsrv.net/gimg/atvconn...33f4f90d26.jpgCorrect orientation?
https://cimg7.ibsrv.net/gimg/atvconn...c40a226711.jpg