why don't you take it to the dealer, sounds like warranty to me

 

The polaris 4wd will engage at all speeds as soon as the front wheels travel faster than the front. There are a couple of things that could cause unwanted engagement. The first most common mistake is using the wrong fluid/oil in the gearcase. You must use Polaris hub fluid or automatic transmission fluid type F. Even though Polaris has a product call "Front gearcase fluid" it must not be used in the gearcase of any Polaris machine which has the new hubless design. Even the dealer mechanics are screwing this up!!!! I have also read about the roller cage being made of plastic on the earlier 02 models, which was changed for an aluminum design to increase the strength or deforming properties. Start by draining a little fluid to see if it's clean and to see the thickness of it. It should be very thin oil and not thick like gear oil. Being you have a 02, you are most likely due for an oil change anyway.

 

I know this may sound like a long shot, but check the top of the shock tower to see if it is tight. I noticed a bit of slop in my 02 700 while replacing a "customized" front a-arm.