Check the wires coming from the circuit board to the wheel. They are very small and get cut from time to time. Another thing is the armater plate in the hub.

 

Thanks, it was the wires to the hub.

 

i had the same problem on a 500. inside the hub thier is roller bearings and a big bearing that engages. their is also a big this flat washer that the magnet sticks to when engaged. on mine i started leaking fluid and i ended up burning the hubs and they wouldnt engage. after i rebuilt hte entire front end as far as new hubs and bearings it was fixed. try the wireing first and make sure it has juice and if that dosent work then start with the hub. i changed the hub first and it fixed it but i went ahead and put all new parts in just in case. sometimes the armater plate can become magnatized and that can be a problem itself because it then fits the magnet inside the hub. hope this helps and let me know i have been threw mine a million times because i bought a bad atv. im down right now

 

i had that issue my hilliard clitch exploded prob because i beat the hell out fo my sportsman in the mud and run huge tires but i replasced everything in the past week but not to thread jack but i cant get my hilliards to grab and sick in my hubs to turn them they spin when all 4 tires are off the ground but if you hold them no good you can feel the rollers slipping inside of the hub and not grabbing

just a heads up if you replace yur stuff and still no luck im working on fixing this problem asap i will let you know what it was.

 

for the magnet to engage the gage and activate the 4wd, there has to be a specific amount of gap in there. It has been many years since I worked on but that would sometimes be all that ws wrong. check you clearance in there if it is too far the magnet cannot pull the cage in. I do not remember the exact specs and exactly where it is to be checked.

 

You are welcome.

 

the gap has to be .001 i know because mine was at .003 and not working properly cookies can guide you to a great link with pictures explaining exactly what to do also ck that the rollers move freely if not line up a file across two of them and slightly file them until the rollers move freely and you will be all set if your wiring is good which again cookies told me to ohm them out

 

i should have told you ,file the slots the rollers sit in but i will tell you .002 made the differance on mine where i could stop the wheel from spinning with on jack stands to it will pull you under the quad and spit you out the back

 

wheres this link at?

i didnt rip back into mine yet but i still only have 3wd not 4

 

SKIDOO, also check your hubs. I have seen a few instances where the inside of the hub where the hillard engages has broken free from the hub and stays in place. Took me some time to find.... If your beating your sportsman as hard as you say. This could be an issue.