2004 sportsman700

when i bought my bike (used bike 3000miles) i didnt notice that it didnt come out of awd so we took apart the front rear end to see if the magnet was still working and it is it works great with switch.so then we had rear end totally apart and found no problems to our knowlege so we put rearend back together and tried with swithch and it worked great so we figured problem solve.WRONG when we put rear end back on bike and tried it all asenbled it stayed in two wheel drive until i switch over to four wheel and it went in four wheel drive then i switched the swith back to two wheel drive and the bike wont come out of four wheel drive! does anyone have an idea wot it could be and is it something that we could fix or should it be taken to a dealer???

Try taking the front hubs apart again and cleaning them out well with kerosene. Reassemble and be sure to use the Polaris oil.

Is the 4wd staying engaged on both sides or just one side? You could possibly have a worn/weak spring on one side, or both sides. If neither of those things takes care of it, bite the bullet and take it to the Dealer.

Depending on the cost of the springs, you might want to just replace them on both sides while you got he hubs apart.

I wouldnt think it is an electrical issue as everything seems to be working ok when you tested it, as you said. Doesnt rule out the possiblilty of the actuator being bad though.

Sounds like a dealer issue to me.

On Hondas sometimes you have to back up a lil for the 4wd to disengage, but the Polaris system is ENTIRELY different.

If the magnets are engaging and disengaging properly with the machine apart, I'd raise the machine up off the ground completely and make sure you aren't getting a false indicator... it might just be a faulty sensor or sender unit/wire.

At 3000 miles if the machine has seen any mud/water those wires and connectors have been subjected to corrosion and water invasion (which means shorts) I'd disconnect all the plugs, clean them throughly and fill them with dielectric grease... if this doesnt solve the problem and the machine is actually staying in 4wd...I'd say take it to the dealer.

Any machine in AWD or 4WD all the time is absolutely NO fun to drive.... good luck with the problem and let us know how it goes.

Ride Safe,

Chuck

Make sure you specify to anyone you ask though that this is a 2004 model, not a 2005 model. This was a changeover year and the 4wd. the 05 front axles engage from the transfer case, rather than the hubs like the 2004.

this machine only has the one magnet and its in the rearend not the hubs

Look at the things I mentioned to you.

Here is the deal on actuators. Doesn't matter who makes them, they have a tendency to weaken and quit working, especially after they get hot or have been used a couple times. This is something that wont show up after you have had the bike torn apart for a while and testing in an environment like that. I would try cleaning the hubs as mentioned, and considering replacing the springs. 3rd option would be the actuator. This is just guesses as I am not working on the bike.

Duplicating the problem woud be the easiest way to test the actuator. When the bike isnt disengaging from 4wd, I would see if the actuator is actually moving anything. Most likely though, it will be taken care of by cleaning the hubs, and/or possibly replacing the spring on one or both sides.

well today i sent my hub to the dealer for repairs ..lets hope it wont be to costly !!!!!!!LOL

Have they finished the job yet? Interested to see how everything went, what their diagnosis was and what they did to fix it

ok i picked up my front diff today from dealer(new seal kit,new armature plate,shop supplies and new drive belt and oh yes lets not forget 1 hour labour on the diff for a total of $356.00 ) and all is well now my machine works in 2 whell drive and awd

Glad to hear that it's working again ....sorry to hear that it cost ya

oh well its fixed and im happy!!!!!!

Not worth havin it the front wheels don't turn!