2005 sportsman 800 awd issue - Polaris ATV Forum
Polaris Sportsman Discussions for the Polaris Sportsman 90, 300, 355, 400, 450, 500, 550, 600, 700, 800, 850

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 19 (permalink) Old 02-04-2013, 08:35 PM Thread Starter
Junior Member
 
under_dog's Avatar
 
Join Date: Feb 2013
Location: armstrong
Posts: 22
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.
under_dog is offline  
Sponsored Links
Advertisement
 
post #2 of 19 (permalink) Old 02-04-2013, 08:40 PM
Polaris ATV Legend
 
Bruce!'s Avatar
 
Join Date: Feb 2009
Location: Port Angeles WA
Posts: 20,004
Welcome to the board!
Bruce! is offline  
post #3 of 19 (permalink) Old 02-05-2013, 10:51 AM
Extreme ATV Enthusiast
 
05sportsman800's Avatar
 
Join Date: Sep 2010
Location: Mauston, Wisconsin
Posts: 103
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.
05sportsman800 is offline  
Sponsored Links
Advertisement
 
post #4 of 19 (permalink) Old 02-05-2013, 01:10 PM Thread Starter
Junior Member
 
under_dog's Avatar
 
Join Date: Feb 2013
Location: armstrong
Posts: 22
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
under_dog is offline  
post #5 of 19 (permalink) Old 02-05-2013, 01:16 PM
Extreme ATV Enthusiast
 
05sportsman800's Avatar
 
Join Date: Sep 2010
Location: Mauston, Wisconsin
Posts: 103
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.
05sportsman800 is offline  
post #6 of 19 (permalink) Old 02-05-2013, 01:23 PM Thread Starter
Junior Member
 
under_dog's Avatar
 
Join Date: Feb 2013
Location: armstrong
Posts: 22
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.
under_dog is offline  
post #7 of 19 (permalink) Old 02-05-2013, 09:21 PM Thread Starter
Junior Member
 
under_dog's Avatar
 
Join Date: Feb 2013
Location: armstrong
Posts: 22
so that was a no go, 4x4 still not engaging
under_dog is offline  
post #8 of 19 (permalink) Old 02-06-2013, 08:04 PM
Polaris ATV Junkie!
 
AKStew's Avatar
 
Join Date: May 2010
Location: Westerville, Ohio
Posts: 919
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.

Stew

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
AKStew is offline  
post #9 of 19 (permalink) Old 02-07-2013, 08:57 AM Thread Starter
Junior Member
 
under_dog's Avatar
 
Join Date: Feb 2013
Location: armstrong
Posts: 22
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.
under_dog is offline  
post #10 of 19 (permalink) Old 02-07-2013, 12:30 PM
Polaris ATV Junkie!
 
AKStew's Avatar
 
Join Date: May 2010
Location: Westerville, Ohio
Posts: 919
Ouch!

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
AKStew is offline  
Reply

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris Model Specific Discussions > Polaris Sportsman

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
2005 Sportsman 400---Charging issue?? MinnesotaMuskie ATV Repair and Maintenance 3 10-23-2012 06:57 AM
2005 Sportsman 500 with fuel?/Electrical? issue CSkjerven ATV Repair and Maintenance 4 07-25-2011 06:35 PM
2005 Sportsman 800 brake issue aalk ATV Brakes & Suspension 4 07-16-2011 05:15 PM
2005 700 sportsman efi running issue drfong ATV Repair and Maintenance 5 12-24-2010 12:01 PM
2005 Sportsman 400 w/weak/no spark issue HELP!! mspeer7 Polaris Sportsman 1 07-16-2010 05:36 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome