I'll walk you through How to fix your AWD (4 wheel drive) on your Polaris ATV from wiring, to checking the hub fluid.
Пікірлер: 131
@danthompson48798 ай бұрын
Hey TG, buy some cheap squeeze bottles for like ketchup/mustard at restaurants. Put your ATF in one, label it. Funnel and juice in one bottle.
@K7classicrockfan5 ай бұрын
I'm stumped, mine (1996 sportsman 500) isn't working on the right side wheel. I changed the coil, and tested it by running the atv and having the rear wheels spin. I can tell the coil is working by how strong it is. Reassembled the clutch (it's new and so is the armature plate), filled the hub with the demand drive fluid to the 3 o'clock position, I didn't use grease . Still won't work. Any ideas??? Any help would be appreciated.
@K7classicrockfan5 ай бұрын
I just fixed it! After 2 years of working on this on and off, the awd being the major issue, I finally fixed it today. I figured out I hadn't tightened the castle nut enough. It needed just a little resistance to help engage the clutch. Now it works!!!
@jimgolden96663 жыл бұрын
Great video, man! Very helpful. Thanks!
@DwightNelson-pm9ul5 ай бұрын
Hello, I have a 1997 Polaris Sportsman 500 and when it's running and I engage it into 4x4 and push the AWD button the whole machine kills. Should I change the ground wires like what happened in this video?
@trxxtinnxr2673 Жыл бұрын
I noticed when i jack up the Polaris and floor it the AWD kicks on when its floored but when you floor it it jerks and breaks the axel due to the AWD kicking on. the wires are still in mint condition and the reverse overide works only if you floor it to. Ive gotten stuck multiple times and it would not spin but one front tire or none of the fron tires. its a hit or miss when talking about the fourwheel drive on the ol polaris.
@ndoomey4 жыл бұрын
I’m having the same issue but can’t really tell which wires your talking about
@uncledave2872 жыл бұрын
Mine is stuck in 4x4 any suggestions?
@chrispappas17662 жыл бұрын
Great video, thanks !...on my 2004 sportsman.500 HO, I noticed on speedo the gear indicator lights were going out...possibly fried speedo ?...would this also cause issues w my AWD ? ....thanks in advance !
@alexanderjanson7073 Жыл бұрын
Same
@donwilder14763 жыл бұрын
i use squirt can marked atf for polaris only for filling
@longbow6416 Жыл бұрын
I have a 99 and 2000 and I commend you for your simple fix and doing the math! Worked on each machine! Both machines no longer have working speedometers and have been replaced by aftermarket GPS heads. I heard that the speedometer head also houses the 'brains' for the AWD. There's a PNP chip and something else that can be replaced to regain functionality but this fix is easier and more reliable. Thanks again!
@TitaniummanGarage Жыл бұрын
Right on! Sometimes you have to take a step back and think about how the wires go...and make adjustments.
@garyeckert20492 жыл бұрын
I’m trying to do the same but only have two grey wires. I believe it’s a 99, but mine does not have that board like yours does in the video. All I have is two grey wires and not one with a white stripe. Any help would be greatly appreciated. You are Polaris man in my book. Lol
@TitaniummanGarage2 жыл бұрын
You have the plug and play style. 2 grey wires and a ground looping to both. I would add a wire to that ground wire and connect it to the frame somewhere. Use a test light first to see if you have power to the 2 grey while in 4 wheel drive first.
@craigcampbell9018 Жыл бұрын
I have a 2001 500 ho put new camshaft in and china 30 dollar carb. Starts right up accelerates good but won't idle no matter what I do with mixture screw. Seems to be hydrastatic locked after it's hot. Any ideas? Thanks
@TitaniummanGarage Жыл бұрын
I would double check the valve lash. Sometimes after replacing a cam after the chain has revolved in the engine a bit it tightens more and throws off the adjustment you set. Also depends what carb you bought. I've had good and bad ones. I must have at least 10 china carbs in a box that didn't work. I use the parts to rebuild the oem carb.
@mattgilbert10754 жыл бұрын
Hello I have a 03 Polaris Magnum 330 feels like my right front tires locking up hard to steer feels like something is fighting any recommendations would greatly help thank you
@b.pur99814 жыл бұрын
I had similar problems. Change your hub oil. Worked for me
@joshgeister4324 жыл бұрын
I have this same problem and am having a hard time figuring out why
@capreolwal3 жыл бұрын
My wheels pull also. Just back the quad up a bit and the wheels seem to release again. 2001 Sportsman
@survivalfreek8 ай бұрын
I have a 96 Sportsman, when I test that grey connection, I'm not getting any power, and the 4x4 light never comes on and the button won't stay in, I push it in and it pops right back out. Any advice to what it could be?
@TitaniummanGarage7 ай бұрын
Its probably shot. You might want to replace the button
@mikepatten45124 жыл бұрын
I have a 1999 Polaris 500 magnam starter got water in it And frooze up changed starter-abendix and starter cylenoid went to start and only cylenoid clicked taken apart twice same thing have to start with pull rope I am 72 years old have a bad heart and towrn rotator cuff this pull starting is killing me need help any tips apreciated
@TitaniummanGarage4 жыл бұрын
Is the starter new? I'm not sure what you mean when you said you took it apart twice. So..you have power to the solinoid but not the starter. Have you tried a new battery? Sometimes the battery will read 12 volts but when you add power like lights or a starter the voltage drops and the starter won't turn. Also look for any broken wires leading up to the solinoid. It could be a weak connection in the wire harness going up to the start button. I believe it's a white wire with red line on it. I had to trace one once. It turned out the start button turned green and corroded on the inside. Not sure if that is your problem only because your solinoid is clicking telling me you have power from the start button.
@TitaniummanGarage4 жыл бұрын
Also check your ground wire.
@travisjohnson84192 жыл бұрын
Thank you for making these videos!!! I have a 2002 Scrambler 400 4x4...4x4 only works in reverse with override button pushed in. Then button is pushed in, the add light on the right control is illuminated, when I release the button, the light goes out. I'm wondering if the Trans Switch is bad? any help is greatly appreciated. Thanks!
@TitaniummanGarage2 жыл бұрын
Try pushing the override button in forward gear. It does sound electrical.
@bluelu002 жыл бұрын
If it’s only doing that in reverse, it’s working correctly. AWD will only work in reverse with the button pushed. Very annoying when plowing.
@stevegiroux239 Жыл бұрын
Okay I’ll check my hubs because I don’t have the 4x4 working in front both wheels don’t spin while engaged
@davidcooley51353 жыл бұрын
I've got a 1993 2 stroke 350 and and it's on demand I let a friend drive it and he done something to it I found that the light was on 4x4 and I turned the switch of and now when u put in high it's like it won't pick up speed but in reverse it's fine it goes fast and now it won't turn on 4x4
@robertbille70597 ай бұрын
It is a 90 it runs but give it gas it bulgs out ?
@benjaminp69246 ай бұрын
Faulty wire connection's
@franklinarguedas48323 жыл бұрын
Hi, would you be able to do us a favour? We need to find out the size of the O ring that goes into the Carburettor and holds the float needle, Internal, external and Cross sectional dimension, I have been ordering through eBay and what I get do not last, they are not Viton O rings, so the fuel kills them very fast. If you know where to get the Fluorocarbon O rings, please tell us, and if it is hard to get them to deliver in Australia, could you buy them for us and send me about 6 of them, I will reimburse you quickly. Regards, Franklin
@kylemccollor16103 жыл бұрын
First off love the videos. I do have a couple quick questions. First off can the AWD switch be lit and still be bad? What do you have your volt meter set on? Lastly where exactly is your neg volt meter attached to? Thanks
@TitaniummanGarage3 жыл бұрын
There is a chance it could be. But if you hook the volt meter set it to 20 volts. Put the black on any ground. You should be able to tell if your switch is bad.
@der6994 жыл бұрын
I have the wires down on the bottom of the strut usually break in cold weather on me on the awd
@TitaniummanGarage4 жыл бұрын
Seen that alot. Sometimes you get lucky and can reconnect them.
@sheliafleming Жыл бұрын
My Polaris is just like this one can I get a few pics of wiring in the front to make sure mine is write
@TitaniummanGarage Жыл бұрын
I don't have that one anymore. Sometimes when I can't figure out a wire harness I will look at someone's video and pause it when it shows the wires I need to see.
@sethdenzak4 жыл бұрын
When you are referring to checking the spacing of the coil and the magnet with .001 feeler gauge, can you explain better how to check this?
@TitaniummanGarage4 жыл бұрын
You have a inner ring, then the magnetic coil,then an outer ring. Take something perfectly strait like a ruler or a piece of metal and go across the whole coil. See if the outer ring is out further than inner ring. If it's more than .001 it won't magnetize. Only the outer ring moves.
@osbornebay944 Жыл бұрын
Thanks again for this vid. my 4x4 not engaging, ll go through electrical and fluid, hopefully it works.
@imacgst273 жыл бұрын
Thank you for the great informative video!!
@2StrokeSmoke5449 ай бұрын
Wonder if that hub is related to my wife.. all dried up..
@TitaniummanGarage9 ай бұрын
lol
@justinlewis54893 жыл бұрын
I thought it was special fluid for the front hubs??
@TitaniummanGarage3 жыл бұрын
You can use ATF as a substitute. It works just as well.
@anthonyg6221 Жыл бұрын
I have a 97 Polaris sportsman 500 that my neighbor gave to me. It has a plow and I figured it'd be great for our property (10 acres in northern WI) I've spent quite a bit of time and money tuning it up and fixed some small issues (No charging, bad starter, bad recoil, etc) over the past couple months. It was stored in the yard uncovered for years so it needed quite a bit of TLC. The last thing is the AWD. I just cannot get it to turn on and drive the front wheels. I've replaced the magnetic coils, Armature plates, (1) of the hillard Clutches, outer seals (Poles), verified clearance between the outer/inner poles which is spot on at
@TitaniummanGarage Жыл бұрын
When you replaced the magnetic coil did you make sure the inner ring is flush with the outer ring...all the way around? I had that issue once. If it's not perfect it loses its magnetic power. Also. I dont torque my hubs to spec. It seems like it's too tight and the hubs dont respond correctly. I just snug them up till there is a little drag. Sounds like you have power. And you grounded it. A good ground is important.
@anthonyg6221 Жыл бұрын
@@TitaniummanGarage I seated the magnetic coil all the way back. I then tapped on the outer sleeve flush to the inner pole. I've been focusing on the right side and last night I got out a machinist scale and shim gauges to double check. It was not perfect (But very close) I proceeded to check all the way around and had to do some minor adjustments but now it is perfect but still no 4WD. I work from home so on lunch break I'm going to go out there and experiment with a very loose setting on the spindle nut and see what happens. I was also just reading how someone had experienced the hardened sleeve in the hub assembly coming loose and spinning inside the hub thus acting like no Hilliard engagement when it actually was engaged. I'll check this, too. Thanks for the quick reply! Where are you at in WI? I'm in Marinette county.
@TitaniummanGarage Жыл бұрын
@@anthonyg6221 I have a cabin near high falls. My shop is in Sheboygan
@TitaniummanGarage Жыл бұрын
@@anthonyg6221 Oh..if the nut is loose. That is correct. The hillard wont engage
@anthonyg6221 Жыл бұрын
@@TitaniummanGarage I'm near Goodman. We just moved up here from the Milwaukee area. Finally can use an ATV and snowmobile from my front door. Totally awesome! Anyways, I went out to the garage and fooled around with it. The torque on the nut had no effect. I did however add 3 small pieces of small diameter fuel hose to the 3 tabs that protrude from the armature plate. My thinking is I needed more pressure on the armature against the magnetic poles. For the first time the right front wheel engaged 4wd! It was intermittent and didn't disengage well by turning off the switch. Going into reverse would disengage it. After I reassembled and added hub fluid it didn't seem to work anymore. The Hub fluid must be too slick and reduced the friction. I might fool around with the fuel hose idea a little more, maybe add a longer piece to add more pressure on the plate. Not sure how long this fix might last but the fuel hose fits perfectly in the 3 notches on the back side of the Hilliard assembly. I think the inner poles are worn down from bad wheel bearings and to fix properly will require new struts which probably won't happen on this machine. If I can get the 4WD to stick on by rigging up with something (Fuel hose) it'd be good enough to plow with. Thanks for the advice and videos!
@ameliasimpson8454 Жыл бұрын
2002 500 Scrambler After replacing the head, the fan is not engaging. Wire to the bottom of the radiator is hot. Suggestions besides the thermostat? Tia
@TitaniummanGarage Жыл бұрын
kzbin.info/www/bejne/mmrNi4iehJZ_gJI
@danieldziedzic85534 жыл бұрын
Have you found a aftermarket bulb for the AWD indicator?
@TitaniummanGarage4 жыл бұрын
No. I never replaced one.
@toms7514 жыл бұрын
TG I’ve been guessing you’re in WI, Sound exactly like Rob, who runs the KEGV airport!
@TitaniummanGarage4 жыл бұрын
I Heard I have a twin running around. Lol.
@renegade97583 жыл бұрын
@@TitaniummanGarage Hi my friend has a 500 sportsman, does the Drive Shaft have to run even in 2 x4 ??
@TitaniummanGarage3 жыл бұрын
@@renegade9758 Yes. depending on what year.
@renegade97583 жыл бұрын
@@TitaniummanGarage xplorer 1997
@renegade97583 жыл бұрын
@@TitaniummanGarage he is Jack on blocks the wheels in the void the propshaft does not turn in 2x4 and no longer in 4x4
@raymondkinley662 жыл бұрын
Why can't I go backwards when I'm in awd
@1_slow5.362 жыл бұрын
if the speedometer don't work the 4x4 wont ether right?
@celticbern3 жыл бұрын
Excellent Information. Thank you so much!
@TitaniummanGarage3 жыл бұрын
You bet!
@Dan-ot4rs Жыл бұрын
I have a 98 that's in 4wd with the switch on or off. Any ideas would be appreciated
@TitaniummanGarage Жыл бұрын
Change the hub fluid. Drive in reverse with the switch off. Sometimes the hillard clutch sticks and won't disengage,
@kurtfoulke51303 жыл бұрын
That wire bundle looks like a rat's nest
@toms7514 жыл бұрын
Thanks,
@osbornebay9442 жыл бұрын
One question : can l test spark without battery and key harness?
@TitaniummanGarage2 жыл бұрын
No
@travisdeanministries1363 жыл бұрын
I tested my wires on my Polaris 500 magnum. The gray wire has 12 volts. Then for the heck of it, I tested the brown and it got 12 volts as well. Brown is ground isn't it? The 4wd doesn't work but can't figure out why I would have 12 volts to the brown wire.
@austinjackson82483 жыл бұрын
I have the same problem the wires on mine are shorted out on both sides between where they split off to go to the hubs and the hubs. It doesn't make sense to me why the would both short out. Just got it but someone else unhooked the ground to keep from arking out
@austinjackson82483 жыл бұрын
Sorry I was wrong it is supposed to have 12v until it actually becomes the ground I don't fully understand why but my dad is an electrician.
@travisdeanministries1363 жыл бұрын
@@austinjackson8248 I got my rig figured out. My speedometer wasn't grounding out the 12v to the coil. This is a known issue with these speedometers. All I did was cut the two wires that goes into the speedometer that are grounds and wire them together. You can still use all the AWD switches as usual and doesn't harm anything. The two wires you cut are the brown with the white stripe and the solid brown. Those are your grounds that need to be tied together. Mine has worked perfectly since doing this. Good Luck.
@stefandedu202 жыл бұрын
I have a polaris sportsman 500 model 2008 and I discovered that it does not engage 4 × 4 in reverse. What could he have?
@TitaniummanGarage2 жыл бұрын
Check the switch on the transmission. It could be bad. Also is your shift linkage good? Does it go in reverse and forward fine? Sometime if it's not all the way in reverse, the switch won't engage on transmission. And make sure you press the override switch. sometimes that's the culprit too.
@stefandedu202 жыл бұрын
@@TitaniummanGarage Thanks for the reply! I admit I didn't know how to press the yellow button. I wish you strength in everything you do!
@jacktrue62012 жыл бұрын
When I flip my switch on my 99 magnum, the front axles still spin but my wheels don’t, could that still be an electrical issue or is that Machanical?
@TitaniummanGarage2 жыл бұрын
It could still be both. I would start with electrical, then check the clutches.
@jacktrue62012 жыл бұрын
@@TitaniummanGarage thanks for the advice I’ll keep you posted on the results I find
@stevegiroux239 Жыл бұрын
Thank you for the video
@adamr86282 жыл бұрын
So, why are the wheels turning at idle? My guess is that the belt drags just enough on the pulleys that the tires will turn when there is nothing holding the tires? And my other question.....I thought the all wheel drive was only on demand? Or does it sense that the wheels are slipping when it's jacked up like that?
@TitaniummanGarage2 жыл бұрын
The second option
@adamr86282 жыл бұрын
@@TitaniummanGarage what do you mean by the second option? I was asking two different questions
@TitaniummanGarage2 жыл бұрын
@@adamr8628 It senses when its slipping. your belt could be too tight or idle too high. Thats why the wheels are turning
@mjjack73 жыл бұрын
Have zero power at all. No lights no dash no 4x4. Can only start by pull cord 02 sportsman 400. Worked fine yesterday. All take ground of some wire unplugged? Any ideas??
@TitaniummanGarage3 жыл бұрын
It starts..so that rules out any kill switch issues. I would start from the battery and work your way up. Battery charged, check connection to starter solenoid sometimes it's a bad ground, loose wire. You almost need a voltage meter to check the rest. It's not an easy answer without testing anything. Make sure your battery ground wire isn't loose or corroded. It could be a number of things.
@TitaniummanGarage3 жыл бұрын
Wait. You have the digital dash right? If the speedo is shot the 4x4 won't work.
@mjjack73 жыл бұрын
Titaniumman Garage has digital odometer only. Nothing electrical works. Cant start with starter but can turn off. No front light or break lights. No gear indication light, no 4x4. Will dig into some more shortly. Too damn cold to work on the right now.
@TitaniummanGarage3 жыл бұрын
@@mjjack7 Pull the plugs going to the start button/kill switch. I had one like that. same issue. the plug wires turned green and wouldn't start. dash wouldn't light up or lights. There should be 2 plugs. I cleaned mine with a cup of vinegar and a teaspoon of salt. let it soak for 15 minuets. It takes the green crap off. unhook battery first. Try adding another ground wire somewhere if you can. If wires are green it means bad ground.
@jeffreyhernandez42982 жыл бұрын
Thank you for you’re help 👍🏼
@michaelchaoticreason50592 жыл бұрын
Hey mate. I’ve been trying to find a work around and I’m getting stumped. I have a 2003 sportsman, and Polaris changed the wiring harness around. 1st, they omitted Gray with white, and I can’t find a similar line anywhere on the harness. And 2nd, I seem to have power to the AWD wires whether I’m in gear or not. I have AWD in H & L, but can’t get it to kick in while I’m in reverse. My override button does nothing. I wanted to omit it so when I plow this year, I wouldn’t need to press it to keep my AWD in reverse. Wisconsin winters and all. I’ve been looking at my wiring diagram to see if there was a spot I could splice into where I wouldn’t need to hit the override button, and bypass the tranny switch, as you did, but I’m not seeing a way. Do you have any ideas?
@michaelchaoticreason50592 жыл бұрын
So, I found the gray with the orange stripe is what comes off of my override switch, but it toggles between my miles, tach, hour meter and voltage. My switch is not working, because I've never been able to toggle between anything. But when I ground out that wire, my AWD does work in Reverse now. But if I leave it grounded, I get a flashing check engine icon on my speedo. If I just touch the wire to ground, I toggle between my choices on my speedo. I'm thinking to hook it up to a toggle switch, so I can turn it on when I want, but hopefully won't give me any issues. What do you think?
@TitaniummanGarage2 жыл бұрын
I would have to look at a 03 wire diagram.Did you see my video on the bypass tranny switch? Without looking at the wire diagram it could be a ground issue. I would double check your grounds. make sure any wires are not touching that shouldn't be that are hot. Is that white wire you spoke of have power to it?
@michaelchaoticreason50592 жыл бұрын
I did watch that video. But there is no gray with white stripe in my harness at all. The 03 has a multi function override button, not just AWD engagement. So to me, it does not seem as straight forward as giving power to it, or even grounding it out, if I understand the wiring diagram correctly. I was hoping you had come across this one before. I’ll rewatch your video on that 700, as that was the same year, but I don’t remember if they had the same functionality in the override switch on that model.
@TitaniummanGarage2 жыл бұрын
@@michaelchaoticreason5059 I was just about to ask. yes the 700 does have multi function. I've been working on so many of these I forgot how the 03 was.
@michaelchaoticreason50592 жыл бұрын
@@TitaniummanGarage . I thought I had watched the video on the 700, but I guess I didn't. On my 500, there were jumper wires on my 4 wheel drive plugs. They looked like factory wires, but there was a jumper from ground to ground and from live to live. I didn't know which to splice into, so on my 500, and I actually saw in your 700 video as well, there is a grey with an orange stripe that comes off of the override button. I cut that and hooked it up to a toggle switch and grounded out the other side of the switch. It solved my issue, and if I just switch the toggle on and off, without being in AWD, it toggles the info on my speedo too! But grounding out the grounds probably would've been a lot simpler... ;) Thanks for all your help.
@NortheastVintage3 жыл бұрын
Mine won’t go into 4wd in reverse even if I press the override button.
@TitaniummanGarage3 жыл бұрын
Check your wiring by the shifter. Clean all terminals for the 4x4 wires. It sounds like an electrical problem. It's just a matter of hunting it down.
@NortheastVintage3 жыл бұрын
@@TitaniummanGarage Thanks!
@NortheastVintage3 жыл бұрын
Turned out to be the purple wire was unplugged. 4wd works perfectly now in forward and in reverse with the override switch pressed!
@connersnow2983 жыл бұрын
Awesome vid and edits and filming and bike
@TitaniummanGarage3 жыл бұрын
Thanks man!
@joshwinters32993 жыл бұрын
Nicely done!
@FarmersforTruth2 жыл бұрын
Hilliard not hillary
@TitaniummanGarage2 жыл бұрын
Yup! I slurred. hahaha.
@alexyochum5648 Жыл бұрын
He corrected himself in the video🤗
@cr-us9ch3 жыл бұрын
Mine won’t disengage
@TitaniummanGarage3 жыл бұрын
It could be 2 things. Either there is constant power to the magnetic coils or there is no hub fluid in it and hillard clutch is froze. Try driving in reverse to get it to unlock.
@fernandoperez61664 жыл бұрын
Cuanto voltaje debe de bajar a alas bobinas ?
@TitaniummanGarage4 жыл бұрын
12 volts should be at the coils
@fernandoperez61664 жыл бұрын
@@TitaniummanGarage Amigo los cables que bajan deben ser corriente ? o corriente y tierra ?
@TitaniummanGarage4 жыл бұрын
@@fernandoperez6166 The Grey wire is power 12 volts. The brown wire is ground
@TitaniummanGarage4 жыл бұрын
Check out this video. It will explain it better. kzbin.info/www/bejne/gaeWaYGbgdV7hZI
@TitaniummanGarage4 жыл бұрын
I'm using a translator to read what you are saying. So where are you from?
@osbornebay9442 жыл бұрын
That is the best looking bird nest! My 2000 Predator all time 4x4 2 stroke, looks like that, scary to 99% folks, good job Polaris!