08 Sportsman 800 4x4 wont engage - Polaris ATV Forum
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post #1 of 14 (permalink) Old 01-22-2011, 06:15 PM Thread Starter
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08 Sportsman 800 4x4 wont engage

After I start playing in the mud my 4x4 wont engage when I put it in hi or low but will engage in reverse if I hit the override button. Has anyone had this happen and does anyone have a fix?
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post #2 of 14 (permalink) Old 01-22-2011, 06:34 PM
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is the display showing the correct gear when you are in H or L? is the AWD symbol showing up when you switch it on?
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post #3 of 14 (permalink) Old 01-22-2011, 07:11 PM Thread Starter
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Yes it shows all the gears and the 4x4 Icon comes on the front wheels just wont pull.
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post #4 of 14 (permalink) Old 01-22-2011, 09:44 PM
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check the gray and brown/white wires that go TO the gearcase for 12v dc. check the gray and brown/white coming FROM the gear case for resistance. should be 24ohms.

make sure to test while the machine is switched on (not running) and in gear H or L - in otherwords display will show h or l gear and 4x4 icon while you test.
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post #5 of 14 (permalink) Old 01-23-2011, 04:36 PM Thread Starter
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Those wires hook up to the front hub on the back side? Just want to make sure I test the right wires.
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post #6 of 14 (permalink) Old 01-23-2011, 05:04 PM
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yes, the wires that go into the front hub coil. should if you can see them under the insulation they are grey and brown/white striped.
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post #7 of 14 (permalink) Old 01-24-2011, 03:21 PM Thread Starter
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Everything checks out ok could it be something else.
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post #8 of 14 (permalink) Old 01-24-2011, 04:39 PM
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have you checked the fluid in the front gearcase? should be to the top of the fill plug threads and should be clean of water and dirt. might want to try to drain and replace it before you move onto tearing the gearcase apart.
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post #9 of 14 (permalink) Old 01-25-2011, 02:49 PM Thread Starter
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ok now I am stumped. I checked the fluid and it was clean so i jacked it up off of the ground and put it in 4x4 and it will try and lock in 4x4. So i put it up to a tree and locked it in and it locked in one time but when i put it in rev and pushed the override button it would not lock in and low and behold I put it back in low and high and it would not lock back in. Thanks for all your help I will try anything.
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post #10 of 14 (permalink) Old 01-25-2011, 04:49 PM
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sounds like your next step is gonna be to disassemble the gearcase, i cannot think of anything else it could be on the outside.
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