Still having 4wd issues.... - Polaris ATV Forum
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post #1 of 8 (permalink) Old 05-20-2018, 04:13 AM Thread Starter
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Still having 4wd issues....

01 sportsman 500 H.O

My 4wd will not engage. Last night i pulled the driverside (left if your on it) hub apart. Found metal shavings in the oil. Yanked the hub, all bearings look good, but the hub clutch has gouges around the backside, however, all seemed to be working properly with the clutch itself.

However, the armature plate doesnt fit super tight into the slots, how tight should it fit into it?

Secondly, how hard should the armature plate stick to the magnet? It stuck but i was still able to peel it off by hand.

The passenger side isnt working either, at all, havent tore into that yet.

However, my speedo and AWD light is working, so i wouldnt think its electrical? But maybe? Ive been reading and reading and still cant really figure out WTF to check.

Im to the point of rebuilding both sets of hubs, but i dont wanna spend 200 bucks doing that if its a friggin wire somewhere.
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post #2 of 8 (permalink) Old 05-20-2018, 08:11 AM
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In the how to section in the Technical discussions forum is a great thread on the hilliard clutches in the hubs. Goes through how it works and how to diagnose problems. There are photos and video with it. Great thread with lots of information!

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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post #3 of 8 (permalink) Old 05-20-2018, 08:42 AM Thread Starter
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How do you get to the how to section?
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post #4 of 8 (permalink) Old 05-20-2018, 09:21 AM
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Across the top of the page just under the Logo is a list across the page. HOME, FORUMS, ACTIVE TOPICS and so on. Click on the FORUMS and a drop down menu will appear. Click TECHNICAL DISCUSSIONS and off to the side another menu comes up with HOW TOs. Click on that and then in the top section you will see a thread titled ATV HUB STRUT HHILLIARD CLUTCH....Open that and start reading. There are a lot of replies so it will take a while if you want to get through the whole thing. Information in the beginning is what you want to start with, but you can ask questions at the end if you don't find the answers you need. Most all of us with the older machines that have the Hub clutches are subscribed so someone will know the answer. Good luck with it! They are not complicated in practice and once you understand how they work they can be fairly simple to repair.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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post #5 of 8 (permalink) Old 05-20-2018, 06:04 PM
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Quote:
Originally Posted by DZG400 View Post
01 sportsman 500 H.O

My 4wd will not engage. Last night i pulled the driverside (left if your on it) hub apart. Found metal shavings in the oil. Yanked the hub, all bearings look good, but the hub clutch has gouges around the backside, however, all seemed to be working properly with the clutch itself.

However, the armature plate doesnt fit super tight into the slots, how tight should it fit into it?

Secondly, how hard should the armature plate stick to the magnet? It stuck but i was still able to peel it off by hand.

The passenger side isnt working either, at all, havent tore into that yet.

However, my speedo and AWD light is working, so i wouldnt think its electrical? But maybe? Ive been reading and reading and still cant really figure out WTF to check.

Im to the point of rebuilding both sets of hubs, but i dont wanna spend 200 bucks doing that if its a friggin wire somewhere.
If you have metal shavings then you need a total refurbishment...both sides. I'd go through both sides in detail clean, flush and replace everything with a wear mark. Always replace the armature plates. They are cheap and there's no reason not to if you're already in there.
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post #6 of 8 (permalink) Old 05-21-2018, 04:24 AM Thread Starter
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Quote:
Originally Posted by polman500 View Post
Quote:
Originally Posted by DZG400 View Post
01 sportsman 500 H.O

My 4wd will not engage. Last night i pulled the driverside (left if your on it) hub apart. Found metal shavings in the oil. Yanked the hub, all bearings look good, but the hub clutch has gouges around the backside, however, all seemed to be working properly with the clutch itself.

However, the armature plate doesnt fit super tight into the slots, how tight should it fit into it?

Secondly, how hard should the armature plate stick to the magnet? It stuck but i was still able to peel it off by hand.

The passenger side isnt working either, at all, havent tore into that yet.

However, my speedo and AWD light is working, so i wouldnt think its electrical? But maybe? Ive been reading and reading and still cant really figure out WTF to check.

Im to the point of rebuilding both sets of hubs, but i dont wanna spend 200 bucks doing that if its a friggin wire somewhere.
If you have metal shavings then you need a total refurbishment...both sides. I'd go through both sides in detail clean, flush and replace everything with a wear mark. Always replace the armature plates. They are cheap and there's no reason not to if you're already in there.
Kinda what i figured. Im going to order armature plates today. The metal shavings came off the back side of the clutch, almost like the cv nuts wernt tight enough and the fingers rotated around and tore the clutch up
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post #7 of 8 (permalink) Old 05-23-2018, 05:30 AM Thread Starter
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Might be getting somewhere, the coil gap was way off, got it adjusted and it seems to be grabbing better, got new clutches and plates coming, hopefully this does it
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post #8 of 8 (permalink) Old 05-23-2018, 06:55 AM
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Originally Posted by DZG400 View Post
Might be getting somewhere, the coil gap was way off, got it adjusted and it seems to be grabbing better, got new clutches and plates coming, hopefully this does it
Sounds like you're on the right track.
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