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Old 11-05-2012, 05:31 AM
Steventabor's Avatar
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Member #31295
Join Date: Oct 2012
Location: Winston Salem NC
Posts: 6
Exclamation 4 Wheel Drive Problems

Hello everyone,

I am seeking help on a 4 wheel drive issue from those guys that know about these things, so if you can help please share. About a month ago I bought a 2007 Polaris Sportsman 800, since then I have had it in for a full service at a certified Polaris dealer. Along with the service several ball joints, bearings and miscellaneous repairs were made. Yet one major issue remains, the 4 wheel drive will not engage. The speedometer works the LCD display shows the 4 wheel drive icon but when in the mud only the rear spins. I can add that the gas gauge does, at times flash displaying random fuel levels.

Thanks guys.
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Old 11-05-2012, 05:50 AM
lost cause's Avatar
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Join Date: Dec 2010
Location: wichita falls, tx
Posts: 2,402
There are numerous things that can cause issues with the 4wd on these machines. Speedo not working, voltage at the diff, too little fluid in diff, too much fluid in diff, dirty fluid, wrong fluid, warped armature plate, or broken sprague cage. In that order. Start by checking the speedo, if that works then move down to the diff. to see if you have voltage. If you have voltage, then drain the fluid and ensure you put the proper amount of the Polaris Demand Drive fluid. If that doesn't work then take it apart and look at the sprague cage. If it is cracked or broken, replace it. Also check the armature plate while your in there. It only takes it being warped .005" for it to cause engagement issues.
__________________
2009 SPORTSMAN 800 H.O.
RUBBER DOWN CUSTOMS 2" LIFT
EPI HD SPRINGS
29.5 S/W OUTLAWS ON ITP SS312
1.5" SPACERS
GORILLA REAR PROP SHAFT
GORILLA AXLES
SUPER ATV BILLET CAGE IN FRONT DIFF.
SUPER ATV ARMATURE
WELDED LOW GEAR IN TRANSMISSION
QUAD SHOP CUSTOMS CLUTCHING
TRIANGLE ATV STEALTH SNORKLE
TRIANGLE ATV REAR RACK PLATE WITH AMMO CANS
RIDE N'REST BACKREST W/FROSTY BEVERAGE HOLDER
K&N AIR FILTER
PURE POLARIS FRONT AND REAR BUMPERS
POLARIS FRONT AND REAR RACK EXTENDERS
POLARIS 3500 WINCH

POLARIS OEM BELT
STOCK EXHAUST
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Old 11-05-2012, 06:45 AM
Steventabor's Avatar
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Join Date: Oct 2012
Location: Winston Salem NC
Posts: 6
Exclamation Follow up

I have a feeling that it is an electrical issue. Originally, the winch wouldn't work when the cooling fan was on and then the issue with the fuel gauge popped up and now I don't have 4 wheel drive, if there are major electrical issues what should I look at in that area? Thanks for your help.
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