You say you have a manual,you may start traceing some wires looks diffcult, but isn't if you have the manual, wash the wiring board off so you can see colors and get with it.I had 96 that wire came off of and lost 4 wheel.If you block it up and pull wheels makes alot difference when you grease it,also you will find underneath that there is hole in belly plate so you can get to grease zirk.

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THE FORMER CORNCOB2

 

How do you think Polaris parts stays in business, they hide the zerks! When it breaks then you find out about them. Sorry I can't help with the hubs.

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Steve Thompson

99 Scrambler 500

 

When I posted about the father in-law and sons wrecking my 335 & 500 sportsmans? The one brother in law thought polaris' could fly and sent it tumbling down the Black Hills in SD?
I finally got enouph dough to buy the basic parts needed and get it going. It runs great, no leaks anymore, but I can't get the 4WD to work. I have juice to the hubs, but they won't engage when the rear spins. Any ideas?
I have taken the hubs apart as far as I dare, replaced fluid, put back together. But still no 4WD. I don't think this has anything to do with the fall it took, because the 4WD wasn't working the week before either. It started working again before it was crashed.
One other thing... As I took that Polaris apart, I kept finding more and more zirks! Some were totally unaccessable unless the front cab was off. Don't get me wrong, I would rather have the capability to do preventative maintenance than not, but atleast tell us about all these zirks in the manual. Anyway, if you guys have any ideas on the hubs, it'd be surely appreciated.
thanks

 

Check the wire all the way to where it runs to the hub. I zip-tied one too tight and it broke apart. (the wire)

If still don't have any luck, e-mail me, I can probaly help you find out the problem with the shop manual.

 

I am not sure if you can tell by this method I will check it out tomorrow. The four wheel drive works by energizing an eleltro-magnetic coil and I am wondering if when energized you could feel the magnetic pull with a screwdriver.

 

I had the same problem, no biggy. It turned out to be a spade connector had come off a terminal on the connector board under the headlight. I believe that during assembley not enough care was taken to ensure the spade connector was put on properly. I will check it from time to time to make sure it is still in place but I am not expecting anymore problems.
Dave Formstone
98 SP500 EBS

 

Don't forget to look at the 4WD button. Mine gets dirty from time to time and I lose 4WD usually when there are a lot of Honda onlookers.