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Discussion Starter #1
Help!
I have a 1996 Polaris Sportsman 400 4x4, that will not go into 4WD...
It does have power to the FWD coil, but it will not go into 4WD in any gear(Low or High, since it is an automatic). Does that mean the coils are bad or is there another piece that is possibly not engaging?
The reference/repair manual I'm using(Haynes) does not offer details/parts diagram for this.
Any or all help is/will be appreciated.
jboc
 

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i would start with a good 'ole fluid change on the hubs. another issue somewhat common is the the cage that holds the rollers can break, sometimes. here is a parts fiche of your front end.



1 7515321 BOLT(10) 8 Usage
2 5211326 DISC, BRAKE Substituted by 5242935 2 Usage
3 3610019 SEAL, FR. HUB 2 Usage
4 5211148 PLATE, ARMATURE 2 Usage
5 1520214 CLUTCH ASM,FR.HUB,E/M,HVY. Substituted by 1520281 2 Usage
6 3554506 BRG,TAPER.ROLL.CONE 4 Usage
6 3554506 BRG,TAPER.ROLL.CONE 4 Usage
7 3554507 BRG,TAPER,ROLL CUP 4 Usage
7 3554507 BRG,TAPER,ROLL CUP 4 Usage
8 1520182 HUB ASM,W/BRG.RACE (Incl. 3, 7, 14) 2 Usage
9 3250028 CAGE, ROLL 2 Usage
10 3250010 ROLLS 12 Usage
11 3250032 SPRING,GARTER 2 Usage
12 3250031 SPACER Substituted by 1321814 2 Usage
13 3250030 CAM 2 Usage
14 7515523 STUD(10) 8 Usage
15 7052045 PLUG,PIPE 2 Usage
16 5410947 TIRE,FR(25X8-12) (25x8x12) 2 Usage
17 1520227 HUB ASM,(3-LOBE)W/BRG.RACE (Incl. 3, 7, 14) 2 Usage
18 5432347 CAP,HUB,3-LOBE,(AWD) Substituted by 5432611 2 Usage
19 7517250 SCREW(10) 6 Usage
20 5431368 CAP, HUB 2 Usage
21 5410470 O RING 4 Usage
22 7710436 RING,RETAINING(10) 2 Usage
23 7543201 NUT,RH THREAD 1 Usage
23 7543201 NUT,RH THREAD 1 Usage
23 7543204 NUT,LH THREAD 1 Usage
23 7543204 NUT,LH THREAD 1 Usage
24 7555903 WASHER(10) 2 Usage
25 7542459 NUT, FLANGED(10) 8 Usage
26 1520179-067 RIM,FRONT(SPORTSMAN) Substituted by 1520269-067 2 Usage
27 1525017 VALVE, RIM
 

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Discussion Starter #3
thank you

Thanks SO much blueline15(especially for the parts diagram), I will see if the fluid change helps. Good info on the cage as well (hopefully not that...).
I bought this ATV with the 4WD inoperable(priced accordingly), because I mainly use it on my cattle ranch and rarely need 4WD---although right now we have 1/4" of ice covered with 7"-8" of snow & it would be nice to have it working!
thanks again,
jboc
 

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no problem! as i have been telling people. i am a parts and sales guy from a polaris dealership at school, so not working there at all right now. but i still have dealer site access, so parts fiche, prices, what fits what, running vin# for warranty and recall stuff...i can do all of that. im not a tech, but i know all the basics. sometimes fresh fluid is all it needs, let me know if it helps any, and we can troubleshoot from there. PM box is always open
 

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blueline just wondering if you can figure my problem out i replaced both armatures in the front hubs replaced fluid with polaris demand drive stuff i have a new battery in it with 12 volts going to the hubs still no 4x4 i have a polaris xplorer 400 1999 i would greatly appreciate any help really startin to piss me off but love the quad
 

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I'm having the same issue on a '98 sportsman 500 except its just to the RF wheel. I have another thread going on this, so if I get figured out, I'll let you know. PLUS, i'll tag along here!
 

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I have just bought a 400HO that does the same thing, it has only done 15 hours so will go back to the old owner and see what the story is.
Am watching your discussion closely as it is a few hours to the nearest dealer! so would be eaiser to sort it myself
Thanks
 

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Sometimes the coil is located too far back on the spindle. That keeps it from grabbing on to the armature properly. This problem made me nuts on one of mine recently....

If both sides not working, I would make sure it's not an electrical issue before proceeding. Hard to believe both sides have mechanical issues at the same time?
 

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if you are not getting any power to the awd switch or the coils you need to check the trans switch located on the shifter on your 400. If the switch is not working right you will not send power to the AWD switch and thus the front coils. This is common on your model.
 

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had mine to the dealer because i couldnt figure it out and was told that my speedo was going bad thus not leting enough power to get to the hub coils but it cost 300 to get it fixed and he wasnt 100% sure about it i might try hooking up a toogle switch to by pass the speedo and will post if it works plowing with 2wd and tire chains for now
 

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Turns out the problem with my 400 was the battery, when i bought the bike it's battery wouldn't start it (had been sitting for 8months) and when i used the pull start it would go for a while and start to backfire, miss and so on, so i rigged a spare battery that i had up to it (not the correct one, just a spare 12v batt i had in my shed!) it had enough power to start the engine but still wouldn't go into 4wd in reverse. once the new battery turned up and was installed - end of problem!! the other battery didn't quite have enough juice to engage the front wheels.
 

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Qiuck question about 1996 Sportsman 400 - Why won't the front right wheel not engage to 4x4? This started happening tonite while plowing.
 

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I can fix them all....take the to the dealership and pay them to fix them.... That's how I roll.....:aargh4:
I took it to a polaris dealer and they said they dont work on it because its too old
I was kidding, but that is retarded... If you are willing to pay them to fix it they should be more than willing. I would say that they don't work on the older models because they don't know how.... Find another dealership.....
 

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I don't want to hijack this thread, but i'm hoping someone can help me out... My 4x4 doesn't work (02 sportsman 400) but there is full power to both hubs. Armature plates and Hilliard clutches are brand new. They magnatize as they should and have correct hub fluid. On jacks. I can stop both tires with my hand.

Another question. Where the splines / rollers on the Hilliard clutch are.. Should there be some notches on the inside of the hub for these rollers to set into when awd engages??

Because with the hub (cover?) itself off, I can see that the rollers move up when the hex nut spins on the axle... I've done the grounding re wiring, grounded the speedo out.. Awd light works, gear selector indicator works, power to the armature plates... Fully/properly magnatized ect. Someone please help :(
 
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