Polaris ATV Forum banner

1 - 11 of 11 Posts

·
Registered
Joined
·
3 Posts
Discussion Starter · #1 ·
Can I put a front diff from a 1997 sportsman 500 into a 2006 sportsman 500 ? Thank you
 

·
Premium Member
2008 800 ho efi, 2019 850 SP premium
Joined
·
5,962 Posts
Welcome to the forum

Your question has now been logged into the queue and the next available forum member will answer you shortly
 

·
Premium Member
2004 Polaris sportsman 700
Joined
·
300 Posts
Depends... does the 2006 have a Hilliard in the diff or one in each hub. If they’re in the hub then they’ll be longer brown-ish ones with bolted on caps.
 

·
Premium Member
2004 Polaris sportsman 700
Joined
·
300 Posts
Upon further review, no you cannot. On older models such as a 1997 there are what are called Hilliard clutches in each front hub. They are round usually plastic cages with metal rollers inside of them that allow the machine to be in 2wd when it’s not slipping, but engage awd when the rear tires slip in relation to the front (when awd is engaged) on newer models, such as a 2006, there is one bigger Hilliard clutch inside the diff that does the same thing as mentioned before. So a 1997 diff is just a right angle gear box, and a 2006 front diff has all the special awd things in it. Not interchangeable.
Exploded view of 2006 diff:
151325

Exploded view of 1997 front diff:
151326
 

·
Premium Member
2004 Polaris sportsman 700
Joined
·
300 Posts
151327

the armature (big round piece on the left) this sits on the side of the diff cover on newer front diffs and fits into the Sprague cage (thicker round piece in the top middle) with usually 7 tabs on the front of the armature. When you hit the awd switch, an electromagnet turns on and through the big ring gear magnetizes the armature plate to the ring gear causing drag on the armature, and in turn the sprague cage. This causes the rollers (lower left) that fit into the cage through the I believe 14 total slots in the sprague cage to be forced into the ring gear which turns the front axles. It’s hard to explain over this and I’m missing some details but that’s the general idea. I’m not very versed on how the hub system like the one on the 1997 works although I have one on my 2004 scrambler.
 

·
Premium Member
2008 800 ho efi, 2019 850 SP premium
Joined
·
5,962 Posts

·
Premium Member
2008 800 ho efi, 2019 850 SP premium
Joined
·
5,962 Posts

·
Premium Member
2008 800 ho efi, 2019 850 SP premium
Joined
·
5,962 Posts
No it is different
 
  • Like
Reactions: Scrappy507
1 - 11 of 11 Posts
Top