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Old 04-03-2010, 09:49 AM
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2002 polaris sportsman 500 4x4 problems

When my switch is on 4x4 my ATV is in 4 wheel drive all the time.
Its always been this way, never thought it was an issue until my buddy drove it last weekend. My clymers book says to feeler gauge it and tap on seal ring to adjust. but it says nothing about which way to adjust. I called a polaris dealer and he said its to complicated to repair if Im not familiar with it. I have changed the boots on it myself, and have rebuilt a 1972 chevelle, so I think I can handle it, just don't know what "it" is. Can anyone help? The book says it should read 0.00--0.025, if it doesnt, than what?
Thank you, Jeff
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Old 04-03-2010, 06:48 PM
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First off, welcome to the board!
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Old 04-03-2010, 07:06 PM
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Thank you, so what do you think about my problem?
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Old 04-03-2010, 07:44 PM
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the outside ring is what you go by. lay a machinist's rule or someother straight piece of stock across the outer ring and feeler guage the inner ring and get your gap measurement but,they don't get off very often . the norm is too wide a gap and the front hubs don't lock in. If the front hubs stay locked in (when in 2 wheel drive),it's usually worn garter springs or dirty hub fluid. you could try flushing your hubs with some kind of solvent then refill ,TO PROPER LEVEL,with hub fluid.
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Old 04-04-2010, 06:20 AM
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My fluid is new and the Hilliards and everything else has been cleaned from when I replaced the boots. This problem has been from day one when it was brand new, just didnt know this was not the right way to operate. It is not stuck in 4wd when the switch is in 2wd, all four wheels are engaged when the switch is in 4wd, I was told the front wheels arent supposed to be engaged unless the rear shaft spins faster than the front wheels are turning. Is this not the case on a 2002? Thank you.....
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Old 04-04-2010, 06:49 AM
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I believe the new style hubs are like that('04 and newer) . To be totally honest ,on my '03 ,i've just used the 4 by 4 switch just to get me unstuck,as it was such a bear to drive in 4x4 on hard pack.
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Old 04-04-2010, 08:21 AM
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Yes it is hard to drive on dry gravel or packed down trails in 4wd! So the 2002 is designed this way, that would make sense, since its been like this from new. My buddy has a 2007 so I thought they were all the same. Thanks for saving me lots of time and of coarse precious money.
Cheers, Jeff
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Old 04-04-2010, 08:48 AM
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It is not supposed to be in 4wd, just by moving that switch over to AWD. Not for the 02. If you turn on the that switch, and then the rear tires break free and spin 1/5 of a turn, then it kicks in. Not before that. You have some sort of electrical issue.
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Old 04-08-2010, 07:39 AM
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Where do you think I should start? Why would this been the way it operated since new? I know they can ship out machines with problems, but seems like a test drive would have thrown up a red flag for the tech. It is very hard to drive in 4wd unless on ice or mud. Thanks cowslinger in advance. Jeff
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Old 04-08-2010, 07:51 AM
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Dont know if Im using this forum properly, just want to make sure Cowslinger got my message.
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