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Discussion Starter #1
1998 Xplorer 300.

First of all, I wired a rocker switch to send power directly to the front hubs because the front hubs were not getting power. I *think* the switch on the shifter is bad (indicators won't light up) not allowing power to go to either the on/off switch on the handlebar or through reverse over ride switch. Something in the system is not working and this was just easier and cheaper than replacing a bunch of switches.



So it seemed either one front hub was not engaging or one side was not disengaging or something causing the front end to pull to one side after using the 4 wheel drive.

So I took hubs apart and cleaned out any funk from the sprags and bearings with kerosene, put everything back together and topped it off with Dexron ATF to the 4 o'clock position (yeah I know).

So far so good as far as pulling. I jacked my bike off the ground and tested the 4WD system.

When I engage the 4 wheel drive, and rev it up a bit, the right wheel will spin. When I disengage the 4 wheel drive system, the wheel stops spinning so that side seems OK.

However the left side behaves kind of odd. It engages as well but when I turn the 4 wheel drive off, that wheel continues to spin.

However if I put the bike in reverse and rev it up a bit, the wheel stops turning then when I put it in forward, it doesn't turn.

So in other words, in order to get the left side wheel to stop turning after disengaging the 4 wheel drive, the transmission has to be put in reverse first.

No biggie but what's up with that? Is this normal?

I was using my Xplorer the other day to pull another Polaris I bought and was spinning the rear wheels because the rear brake was locked up on the one I just bought. I engaged the 4X4 system and then the rear wheels stopped spinning. So the 4 wheel drive system seems to be working fine now. And no unusual pulling after turning the 4 wheel drive system off.
 

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So in other words, in order to get the left side wheel to stop turning after disengaging the 4 wheel drive, the transmission has to be put in reverse first.

No biggie but what's up with that? Is this normal?

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Yes. The owner's manual on most models of this era says whenever 4wd binds (stays on and pulls) after disengagement, to put quad in reverse for a couple feet then forward. Works for me too whenever it happens to occur. Whew! :cowboy:
 

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Discussion Starter #4
your switch has a bulb in it. If the bulb is bad won't engage

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I must have missed that in the wiring diagram.

OK sort of like the battery charge indicator on a car. If the bulb blows the regulator won't get power and the alternator won't charge because the bulb is wired in series with the regulator.

I noticed the 4X4 would not light up on the switch. I realize I could have troubleshooted each and every one of these switches and get the 4X4 to function like it was designed to from the factory.

I just assumed if the switch on the shifter was bad (which costs over $100) it was the broken link in the chain.

With that in mind, I try to be carefully and not give it hell in reverse in 4 wheel drive and flip the bike backwards.

Actually the only time I ever needed 4 wheel drive was when trying to pull my other "dead" Polaris into my storage building. I've driven my Xplorer through a muddy creek trying to spin out and throw mud everywhere in 2 wheel drive and never could get it stuck! I wish my riding mower had the same traction.
 
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