polaris sportsman 4x4 trouble

[ronniediguer]

hi, i have a 2002 polaris sportsman 700. i ride it pretty hard in the mud and im having alot of trouble with the 4x4 like breaking roller cages and it being stuck in 4x4 or having no 4x4 at all. does anyone know how to permanatly lock the front hub so it becomes full time 4x4 in forward and reverse? just wondering if it can be done thanks.

[Bruce!]

Welcome to the board!

[kcaves]

i don't think u can lock it in all the time, u can cross reference the part number to a john deere number for the roller cage, they are metal, that could solve your problem

[ronniediguer]

last time i fixed it with a john deere gator roller cage but i think it broke again because its stuck in 4x4. the day i fixed it, it became stuck in 4x4 later that day after not very hard riding. it would be stuck in 4x4 and the switch would not change it to 2 wheel but it would randomly come out of 4x4 and it would be stuck in 2. im having alot of trouble with this not working right and if you have any ideas that would be great

[Xploder]

Wish someone like Warn would make manual hub's, is your hub's have hilliards on each wheel or is it locked in the front diff?

[ronniediguer]

mine is locked in the front diff

[ronniediguer]

could someone give me a good understanding of what goes on in the front hub to make the 4x4 work? i would be happy with making it full time 4x4 if possible. im willing to weld in the front hub if its possible to lock it up permanatly

[800sport]

I think I read an article in dirt wheels once in the (dialed in section),can't remember how long ago but a guy was having trouble with his sportsman's front diff. if I recall it seamed they said there was a way to permanently lock the front diff in,I want to say it had something to do electrically because that's how the front diff works by sensing slip from front to back,maybe you can locate this article there somehow

[ronniediguer]

is it correct that the 4x4 engages once the rear wheels slip? if so where is the sensor? i think mine must be broken because my 4x4 engages very harshly once the rear wheels are spinning fast but wont engage at low rpm usually

[800sport]

I believe it works off from magnets and an electrical coil very possible you have something wrong in one of those area's,I had a 2002 500 sptmn but never had any issues with the system,didn't mean I couldn't have, wrecked in Harland KY with less than 2000 miles and was totaled