AWD Hubstrut Hilliard Clutch Troubleshooting/Diagnoses - Page 16 - Polaris ATV Forum
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post #151 of 183 (permalink) Old 04-28-2017, 03:52 AM
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Awesome! It pays to dig

Old tech threads well worth re-posting.

First ride:My brother's old Baja 500 entry sponsored by Bushmaster body corp. *not 1000 miles years ago....
Tubular frame buggy, Porsche jugs machined to VW block, " Pat Rutledge machinist" a VW bus close ratio transaxle & turning brakes.
My dad bought it for me to learn how to drive @ 10 & I been hooked ever since passing along the adrenaline to offspring for decades.LOL
Current rides:2015 570-a keeper 2016 570 X2-a keeper 2012 550 X2-selling
Past rides:2008 800HO red Sportsman, sold. 2008 800 HO Sportsman X2 stolen. & pizzed 2009 RZRs, sold.
Too many scooters to mention so lets go with the rare ones I need to kick myself for parting with.
1979 Honda CBX filled with Ontario Motor Speedway parts, Yoshi 6 into one & gummy bear PZ2s on the street.
1979 Kawasaki Z1R-TC only 500 made 10.32 quarter mile stock. $4400. when new in 79.
Used one just sold for way over 100k... hindsight is 20/20
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post #152 of 183 (permalink) Old 05-01-2017, 04:31 AM
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Quote:
Originally Posted by FarmerSid View Post
Hey All! Lost 4X4 on my left front a while ago on my 2002 Sportsman 500X. Took the hub apart and found a bent armature plate. All was good and clean. Got 2 two new armature plates and decided to do both sides and change fluid. Tore everything apart, cleaned everything and put in new armature plates. Filled hubs to 4 oclock position and tried 4X4 and now have no 4X4 at either front wheel. New fluid is part #2877922. Fluid I had but didn't have enough is part #2871654. I didn't have enough fluid so I bought more. The fluid I did have is bluish in colour and thin. The new fluid is yellowish and a bit thicker. Don't know why 4X4 doesn't work now. Light turns on at handle bar when I engage 4X4. Axles are turning from front diff to hubs. I never measured out 5 ounces that each hub needs. Just filled, rotated tire a few turns, check level again. Did this 2 or 3 times to make sure fluid filled all the bearings and got an accurate reading. Tightened fill plug when fluid came out at the 3:30 to 4 oclock position. Was really suprised that I had no 4X4. Front right worked fine before. Did I add too much fluid or should I measure out 5 ounces and only add that amount.

Any ideas?
Did you change anything else ? Are the plates Polaris brand or aftermarket ? I know these things are VERY picky, and I know quite a few people that have had issues with aftermarket plates. Also, I'm not familiar with the fluid part numbers, but again, I know they're picky. Should probably get the correct fluid for it.

08 Sportsman 800 Touring- EPI clutch turning 27" Mega Mayhems, 2500lb Polaris winch, front & rear SATV brush guards, front rack extender, 3 headlight Mod, Quadovator temp gauge, RAC Engineering reverse/ work lights, EBC brakes, Triangle ATV Stealth Snorkels, RDC radiator relocation kit, ATVtrailtunes split tube system, 12" Totron LED lightbar

08 RZR 800- SATV +6 offset long travel kit, Rhino axles, Walker Evans shocks, QSC clutch turning 27" Mud-Lite XTRs, 3500lb Polaris winch, 09 RZR-S exhaust, EMP 1/2 windshield, Air box relocation w/ custom snorkels, EBC brakes, BoeschBuilt parking brake, ATVTrailtunes speaker set, dual LightItUpOffroad LED whips, 30" Totron LED lightbar, 2x3 OPT7 cubes

05 Scrambler 500- Polaris rear rack, Bear Claw tires, EBC brakes (the wife's bike)

Grandkids- 04 Predator 50 (70cc big bore kit), 05 Eton Viper 90R, 93 Yamaha PW50, 03 Yamaha PW50, 09 Kawasaki KLX 110- They're killing me, lol)

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post #153 of 183 (permalink) Old 05-03-2017, 06:15 PM Thread Starter
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I don't think overfilling is a problem. I've done it and had no troubles. The correct fluid is very important.
Did you check the armatures for magnetic pull while you had the hubs open?

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post #154 of 183 (permalink) Old 06-03-2017, 10:19 PM
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Is there any way to bypass the speedo on a 2006 sportsman 700 to make the 4x4 work

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post #155 of 183 (permalink) Old 06-04-2017, 08:57 AM Thread Starter
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Quote:
Originally Posted by mikebourne1966 View Post
Is there any way to bypass the speedo on a 2006 sportsman 700 to make the 4x4 work

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Don't have a schematic for the 700. Couldn't say.

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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.
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post #156 of 183 (permalink) Old 07-15-2017, 05:59 PM
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Hey muggzy great write ups ! New to the forums and I was pointed your way. I have a 06 sportsman with hilliard in front differential. My awd is working fine when selected however to disengage it I need to shift into reverse then back to forward to get it to completely disengage.

I replaced armature plate and when bench tested with power removed the plate stays magnatized until I pull it off or spin the prop shaft in reverse.


Thoughts?

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post #157 of 183 (permalink) Old 07-17-2017, 05:46 PM Thread Starter
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Hey Littledoo,
I don't know how that could happen in the hubstrut Hilliard clutches (what I have) so I don't know how to relate it to the single clutch in the center. Not sure what to tell you.
Muggzy

'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.
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post #158 of 183 (permalink) Old 07-19-2017, 03:14 PM Thread Starter
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Quote:
Originally Posted by Littledoo380 View Post
...
I replaced armature plate and when bench tested with power removed the plate stays magnatized until I pull it off or spin the prop shaft in reverse.


Thoughts?

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While I was learning how the thing worked, I did notice that there was some residual magnetism, but it was pretty light and I don't think it would be enough to hold the armature plate hard enough to keep the clutch engaged.
Now that I'm more awake than when I first responded, I realize the content of the last paragraph. You said "bench tested" but you "spun the prop shaft" did you have the whole front section containing the Hilliard clutch out of the vehicle? Did you actually measure that there was no voltage at the coil or the connector going to the coil? If you did, was the connector physically disconnected from the source? Again this brings me back to the voltage at the coil/connector. If there was a short to the coil wiring, that might keep the coil energized, but should show at the connector with a meter.
Just thinking out loud here. As I said, I'm not familiar with the single clutch machines.


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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.

Last edited by Muggzy; 07-19-2017 at 03:20 PM.
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post #159 of 183 (permalink) Old 09-24-2017, 06:42 PM
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Thanks for the reply muggzy sorry I had totally forgot I had downloaded this app and just getting caught up on my messages.

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post #160 of 183 (permalink) Old 02-01-2018, 11:18 AM
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Great thread Muggzy. Wish I had seen this earlier before I bought a $40.00 ATV polaris manual that was worthless from haynes.
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