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Old 02-04-2013, 07:35 PM
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2005 sportsman 800 awd issue

ok my buddy brought his quad over it had no 4x4, we drined the fluid in the front diff, only to get about an once of oil and half a cup of mud,we than ripped the diff out tore it down found the plastic cage was broke into a millon parts, replaced the cage bearings seals, put it back together, before re installing it we plugged it in, now my question is will it engage sitting on the front of the quad or do the rear wheels have to be spinning to engage it, cause right now if you spin the input shaft by hand it does not engage, checked everything all seems to be good 11 volts at the plug,about 23 ohms on the magnet, just wondering were to go next thanks.
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Old 02-04-2013, 07:40 PM
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Welcome to the board!
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Old 02-05-2013, 09:51 AM
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You should be able to hear or feel the magnet engage. If u spin the input shaft (pinion) both axles should turn, disengaged they should not.
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Old 02-05-2013, 12:10 PM
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with the case apart, and plugged in with 4x4 turned on the magnet holds the plate, but you can still turn it almost like there is not enough hold on the plate, took the case to 2 pokaris dealers one says it is fine nothing worng and one says there is not enough ohms, not to sure what to think
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Old 02-05-2013, 12:16 PM
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Sounds right to me, all the mag has to do is put a small amount of hold on the cage to engage the rollers. You should be fine.
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Old 02-05-2013, 12:23 PM
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yup talked to my buddy about it, we are going to throw it in, only takes about 20 minutes to get her back out and see what happens.
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Old 02-05-2013, 08:21 PM
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so that was a no go, 4x4 still not engaging
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Old 02-06-2013, 07:04 PM
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On Polaris's AWD system, the front diff won't engage unless the rear wheels are turning. Simply put, the speedo controls engagement by measuring the differential speed between the front and rear axles. If the rear spins faster than the front AND does it for 20% of a rotation, then the front engages. That's the primary difference between AWD and 4WD.

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2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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Old 02-07-2013, 07:57 AM
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yeah that makes scence akstew cause the armature plate has to spin the roller cage so far before it pushes the rollers down far enough to grab everything, my buddy took the entire diff to polaris and they ended up desciding it was the magnet was shot, so need less to say another 450$ and we should have it all back up and running, thanks everyone for all the advise.
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Old 02-07-2013, 11:30 AM
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Ouch!
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2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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