Demand drive questions - Polaris ATV Forum
ATV Repair and Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

 
LinkBack Thread Tools Display Modes
post #1 of 10 (permalink) Old 07-22-2012, 10:29 AM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
Question Demand drive questions

I have an 06 500HO with high miles (5500+)... Awd wouldn't disengage so I pulled the front section out to find typical worm components including what looked like warped armature plate. The wires to the coil were frayed and one broke while I was removing it. I bought a used 'good' unit and hooked it up before I put it in. AWD function worked with my bench test so I installed it. Now it won't engage. Key on I get around 11.5 volts through the connector, running is at 13+. I drained and filled it with fresh demand drive fluid, still no go... Resistance on the coil is 27.9 which is high according to the book. What suggestions for my next attemp to figure it out? I tried searching but didn't have much luck. Thanks in advance for your help!
divit250r is offline  
Sponsored Links
Advertisement
 
post #2 of 10 (permalink) Old 07-22-2012, 12:48 PM
ATV Enthusiast
 
xpsteve's Avatar
 
Join Date: Jul 2011
Location: wellsville, ohio
Posts: 48
I would disconnect the wires to the coil and check for continuity from each wire to the diff case. Coil could be shorted to ground.

Steve


Sent from my iPhone using Tapatalk
xpsteve is offline  
post #3 of 10 (permalink) Old 07-22-2012, 03:03 PM
Polaris ATV Legend
 
Bruce!'s Avatar
 
Join Date: Feb 2009
Location: Port Angeles WA
Posts: 20,004
Welcome to the board!
Bruce! is offline  
Sponsored Links
Advertisement
 
post #4 of 10 (permalink) Old 07-24-2012, 01:14 PM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
Quote:
Originally Posted by xpsteve View Post
I would disconnect the wires to the coil and check for continuity from each wire to the diff case. Coil could be shorted to ground.

Steve


Sent from my iPhone using Tapatalk

No continuity to the case but it makes me wonder if the case needs extra ground? Grasping at straws now.
divit250r is offline  
post #5 of 10 (permalink) Old 07-24-2012, 03:05 PM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
Quote:
Originally Posted by Bruce! View Post
Welcome to the board!
Thanks!
divit250r is offline  
post #6 of 10 (permalink) Old 07-27-2012, 03:36 PM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
Bump... Any body have another suggestion?
divit250r is offline  
post #7 of 10 (permalink) Old 08-11-2012, 10:31 AM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
Angry

Another update: I tore the front end apart again, replaced the armature plate, and just ran a few little tests. No matter what I've done so far, the hilliard won't engage and lock the front in.

Resistance through the coil is 27.2 Ohms, voltage at the connector is 10.xx with the key on, engine off. High 13s, low 14s with the engine running. After I hook up the wire connector for the demand drive unit, the voltage across the wires down by the case is only .2 volts.

I will be able to do a comparison on my cousin's '04 400 later this weekend, but I can't believe that it will test similar to the one I'm working with.

Any new suggestions? Can the coil be removed / replaced from the front housing, or am I royally screwed at this point?

Scott
divit250r is offline  
post #8 of 10 (permalink) Old 08-13-2012, 03:53 PM
Junior Member
 
animalcrackerz's Avatar
 
Join Date: Aug 2012
Location: Wisconsin
Posts: 22
Did you replace just the armature plate or the part the wires go to also?



Sent from my Lifeproof iPhone using Tapatalk
animalcrackerz is offline  
post #9 of 10 (permalink) Old 08-13-2012, 04:20 PM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
I only replaced the armature plate, I'm worried the coil is bad now. Based on what I posted above, is there any ouwr explanation? Can it be replaced without buying the $300 side plate?
divit250r is offline  
post #10 of 10 (permalink) Old 08-25-2012, 05:55 AM Thread Starter
Junior Member
 
divit250r's Avatar
 
Join Date: Aug 2010
Location: Northeast Indiana
Posts: 8
Talking Update

For future reference in case anyone else runs into a similar problem:

The root cause of the issue with the front drive not locking in is that the switch circuit lost / loses ground under load. The orange wire to the front drive is +12 volts, and the other wire is the ground.

I used a 400 sportsman to trouble shoot, and my diff locked in and released just like new. Back to my quad, we had +12 volts, resistance on the coil was a little high (28 ohms), and when I hooked up the connector, voltage across the wires dropped to 2 - 3 volts. Use test leads to connect power and jump the other side to chassis ground and everything works great.

Long story short, I will tie a new short ground lead into the quad side of the connector, factory switch will actuate the drive, and I don't have to buy a new side cover for $300 to find out the coil isn't the problem.

Thanks for the suggestions, and hope my book reply helps someone in the future.

Scott
divit250r is offline  
Reply

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris ATV Technical Discussions > ATV Repair and Maintenance

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Demand drive play.... kurt1963 ATV Repair and Maintenance 0 06-03-2012 11:29 AM
polaris demand 4 drive rewire Firecat225 ATV Repair and Maintenance 2 01-23-2011 06:07 PM
250 trail boss 4 demand drive ktmahc ATV Repair and Maintenance 7 05-27-2010 08:54 PM
Polaris Demand Drive Plus fluid bandit59 ATV Repair and Maintenance 5 03-01-2010 10:20 AM
demand drive fluid scott09 Polaris Sportsman 4 02-01-2010 08:24 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome