I'm sorry this is so long, but I have a long,on-going problem. Please read and give any in-sight. I have a 2002 SP 500, and it has been in the shop more than I've had it, and the dealer isn't much help. Here's the story:
I bought the ATV last Oct. I ordered a winch the day I bought it, and put it on myself w/o problem. As I wired in the winch, I wired it to the reverse override wire(that was my fault, I don't know much about electronics, but learned real fast), and when it didn't work, took the wire apart and put a new piece to make sure the wire wasn't crushed and had no more trouble out of it. Here's where the problem starts. Last January I was riding it one cold morning, and the left hub locked up in reverse. Keep in mind this is 3 months after I put the wires back together right. I called my dealer right away, and he said because it was cold, I probably had water in the hub and it had froze, causing it to lock. I had 180 miles on it, so I decided to let him go ahead and do the break-in maint. on it while I had the money. He changed the fluid and finished the maint., and sent me home. I locked again first thing in the driveway. Two weeks later, I took it up for the second trip with this problem, plus I wanted to put on some HD front springs, and told him it was still locking up, so he changed the fluid again and sent me back home. Of coarse it never locks at the dealer parking lot, but again, first thing at home it locked up, and the next day, I also had a puddle of hub fluid under the front wheel. I'm currently in paramedic school, which takes alot of time, so it was about a two to three weeks before I had a chance to get it back to him, not to mention not being able to ride it any due to the leak. This third time, when he took the hub apart, the very outer tapered hub bearing was dented to the point it wouldn't turn. He said that had been the problem the whole time, and changed the bearing, changed the outer seal around the hub cap that had been replaced side-ways, to the point it would not seal and was torn, and once again sent me home. I wondered if the bearing was the problem, and was so obvious, why he hadn't caught it sooner, but was just happy to have it fixed. When i got home this time, it not only did it with the left side, but this time it would do it with either hub. I took it back to him for a fourt trip, and he said he would call Polaris and see what they could suggest. He kept it for two weeks, changed my armature plates, and said it was fixed, again. This time it did it worse than ever, pulling to either side in both forward and reverse. The next day I took it back to him for the fifth time and told him to call when he knew it was fixed, that I was tired of making the 100 mile round trip 2-3 times a month. This time he replaced the whole awd/throttle switch, the whole switch on the left side(headlight, override, kill switch), and every single mechanical piece in the hubs, even the whole strut assembly, and it was still not fixed. He then stated he thought it was an electrical problem, and found where I had cut the wires and put them back together. He said that this was causing the problem and I needed a new wiring harness, at a cost of $230.00. He said the warranty would not cover it, because the wires had been cut, but that he would give it to me at his cost, plus labor, and that he was so sure this would fix it, he would not charge me anything if this didn't solve the problem. I told him I didn't think this was causing the lock-up, because the problem started 2-3 months after I cut and re-tied the wires, but told him to go ahead and replace it, and low and behold, the problem was not fixed. He then said he would try one more wire, the speed sensor wire, and the speedo, and if this didn't fix it, he was at a loss. He replaced this wire, and it didn't do it again at the shop, so he said, so I finally brought it home, after 7 weeks this time. I took it riding last week, and guess what, it still locks up in reverse !! I called him on Tues. morning and told the owner, he said he would call Polaris and call me back before the end of the day, and by 4:30 today(THURS), still had heard nothing, so I called and his mechanic stated he thought the owner was going to call today, but he didn't know if had had got around to it, and to call back in 5 minutes to see. I called back at 4:45, and he was on the other line, so I left a message for him to call me before he left today, but guess what, he never called. I'm at my witts end, and have no clue what to do. If anyone has any ideas, please suggest them. A friend said that after 3 problems with a new product, it would qualify for the lemon law, I've thought about getting all the work orders, and trying for it, but I don't know much about the process to take. Sorry this was so long, but I wanted to get my story and problem out there to the readers of this forum for some ideas. I would be happy if he would just give me a decent amount for a trade-in on it, it has less than 225 miles on it, but I can't even talk to him to see. I don't think this was anything I did, or they would be able to fix it. Any help is greatly appreciated, and thank you all in advance.

Andy

 

You mention that the hub locks in reverse a lot. Is this with the AWD switch disengaged or when it is engaged and also holding the override button? If the switch is disengaged then there is something wrong with your hubs. However, if it is locking only when the AWD switch is on and with the override button pushed, and then one hub or both stay engaged when coming from reverse to forward, then this is completely normal. My old 96 500 frequently locks a hub when going from reverse AWD to a forward gear. This is mentioned in the owner's manual, at least on the 96. My 700 has even locked in AWD going from reverse to forward, even though they said the centralized hilliard front end should eleminate that. If I haven't told you anything you didn't already know sorry about that, but a guy I know kept complaining about his locking up the way I mentioned and thought something was wrong with his bike until I told him about it.

 

Sorry man, but I cannot see how sticking hubs makes the machine a lemon!

I believe that the spindle nut torque is a big factor here, and often improperly done. Also, the armatur plates can get bent if they fall out of place.

I think the dealer is more at fault than anything, especially for not testing more thoroughly and/or going over the ecact sequence of events causing this problem...

 

I guess I should have clarified the problem better. One hub or the other will lock up in reverse w/ the AWD switch "on", even w/o the override button being pushed. It locks to the point that you have to pull forward to straighten out the handlebars, and turn off the AWD, then try to back up again. Even if the front wheels haven't been locked in in forward. It is no longer isolated to one side, they both do it. He said my armature plates were wearing evenly, but has replaced then twice, along w/ every other replacable part. I've tried to do some research on this forum about the problem, so in the past I've asked him about the torque on the spindle nut, and said he has torqued it to specs. I guess it's not really a lemon, I'm just unhappy with the fact it's spent more time in the shop this summer than it's been home, and it's still not fixed, and he won't return my calls. Thanks again for any insight or help.

Andy

 

Sounds like you have a "parts changer" mechanic at the dealership. You know, keep changing parts until its fixed. If they knew anything about the mechanics of the 4x4, they would know that even if there was an electrical problem, you hubs should not stay locked in. Remember, when the 4x4 is on and operating properly, the hubs are energized and engagement/disengagement is almost seemless. You should hardly know they are locked in (except for all your 4x3 buddies that got stuck in mud hole you just went though) Remeber, they should only lock in when the rear tires slip a little.

Almost everyone has had thier hubs stay locked in at one time or another, it is a common problem. Usually, a quick blip of the throttle in reverse will pop it out.

I've never had the hubs apart, but reading the forums and looking at the schematics, its not rocket science.

As far a being a lemon, I don't think so. I'd have a real heart to heart conversation with your dealer. He obviously is flying by the seat of his pants.

 

go watch the polaris atv safety video at the dealership.
this states that a hub can sometimes lock in forward or revese.
it's purely a mechanical thing and not electrical.

other than that the only thing i would check is the torque on the spindle nuts.


and if a side does lock, drive in the opposite direction (fwd or reverse) to unlock the hub.

the newer polaris's are switching to the inward hillard setup partially because of this.
(like on the new 700's 600's and 330s)

 

That really sucks about having to take it in so many times and it is still not fixed. Get a descent trade? Hell no, the thing is brand new, you should not have to lose any money just because your dealer cannot fix it. Can you take it to a different dealer to look at it? I had some problems with my BB and one dealer told me they wouldnt even cover it, so I took it to another dealer and they fixed the problem right away. I know with yamaha's warranty it is good at ANY yamaha dealer. Maybe try taking it to another Polaris service center?

Good luck,

Mike

 

Sorry I'm so late to post on youre dilemma. I to had some problems with my front hubs and was frustrated with them. I learned alot from my dealer only because I'm a loyal customer and he knows I buy parts from him when I do my own repairs. I recently had my hubs apart and re-assembeled them, turns out I way over torqued the castle nut when finishing up the reassembly and did a fair amount of damage. THE TOURQING OF THE CASTLE NUT IS CRUCIAL TO THE PROPER OPERATION OF THE HILLARD CLUTCH. Because Polaris states a torque rating to be a certain amount doesnt make it gospel. If you torque to spec and still have the problem try retorqing it to a little less. Just be sure in the end to shake the tire while mounted, if there is free play then its too loose. Dont make the mistake I made and torque to foot pounds, it is inch pounds. youre shop manual has a conversion chart in the front for ratings.To end a long story, I retorqued my hubs 5 times before they were just rite, don't be fooled you got a great machine you just need to get thru this dilemma.
OH, by the way GET A NEW DEALER !!!

 

I like to get all 4 wheels in the air and test that way.

Cycle the switch obn/off and see if they free up.



Mine did it somewhat when new, but sent away. I just had the LH side apart and when I tested it, it worked perfectly. The RH side was sticking but after a quick spin, it started working again.

I kinda think that insufficient torque actually causes this. My idea is that it lets the spindle "****" in the bore creating side thrust on the armature plate.

 

with the AWD switch ON, my '01 SP500 locked one of the hubs in reverse quite often.....this is NORMAL......read your Owners Manual!

-MT