97 Scrambler 500 Front Hub Issue
 

So the kid that owned this Scrambler before me thought it was a great idea to literally rip out the AWD wires going to front hubs. One side I was able to solder new wires to it and works fine. The other side was ripped right from the coil so I replaced the coil and coil sleeve, got my clearances all good and it worked fine also, for all of 10 minutes. Now that side doesn't work, it's getting voltage down the wires, I'm just getting ready to tear back into the hub. Can anyone give me an idea what to look for when I get in there, as everything is new, except for the armature plate and hilliard which looked fine, I cleaned it up and re-installed, and everything worked fine for 10 minutes.

I would have replaced the armature plate anyway because it's a cheap but critical part. If you didn't let the silicone dry long enough possible the sleeve may have moved back to where the plate may not ride flush against the sleeve and the inner pole of the strut. One thing you can try before you tear that side down is to make a better ground for the hub coils. That's solved a lot of problems on awd engaging for others. Here's one on a Sportsman 500(same system) that he solved his problem.

Do you think it's possible the Hilliard clutch is messed up ? I took it apart to clean it and carefully, taking care not to stretch the springs and after I put it together, I read in the manual they should never be disassembled or they should then be replaced, but I ran it and it did work so I thought OK ?

I've taken plenty of hilliards apart and stuck the bearings back in.Can only remember a couple over the years where a garter spring was stretched or sloppy and I had to replace it. Odds are it isn't that.