Everything I know About Polaris On Demand Drive

[@bobsimpson3774]

You are very good and clear with your explanations 👍

[@rapiddave9313]

You my friend are amazing. So much info and explained so well! You are definitely an authority on these old machines.

[@adamap1]

Amazing video! I just bought this exact model and am watching all your videos. Super helpful. Thank you!

[@longbow6416]

Excellent information! I have a 2004 500 sportsman, helped me understand the system and it's issues.

[@skiptaggart8116]

Great detailed explanation ! It sure helps to actually see the internal hub workings. Thanks for posting this vid!

[@rapiddave9313]

Awesome video! Thanks so much for making this. I just got a Big Boss 6x6 and am about to go down the troubleshooting road for the front wheels.

[@MrFixit1]

I hope this helps! Thanks foe watching

[@michellealms3238]

You amaze me! You know your stuff!! Always learn so much from you. Thank you!’

[@MrFixit1]

Thank you for watching

[@danielmiller8490]

Very helpful vid. I didnt have to take it all apart to see how it works

[@joefuria4344]

That was a great video. Thank you very much for sharing your knowledge. 👍

[@MrFixit1]

Thank you for watching

[@JS-gx8gh]

Thanks it's helpful.

[@djodjodubois9458]

I would have liked you to make a video showing how the lifts and or when the wires are pulled out..how to put them back..thank you I notice that..a 250cc and a 400, are identical so I will be able to put A 400 in my 250

[@MrFixit1]

I'm not sure what you mean by "lifts and or the wires are pulled out"

[@DaizhaFish]

u helped me with all my issues and its running great but it wont move goes in gear but when i give it gas it boges down sat for 10 years could the clutch be frozen ty for all the help

[@MrFixit1]

Pull the clutch cover off. rodents like to make the clutch cover a home.

[@goracegoa1808]

I don't have any 4x4 buton but it's has same hubs demand 4 drive hubs 4x4 is on but no wires come out of the hub for the hubs??

[@MrFixit1]

What is your question? I don't understand exactly what you mean. Can you rephrase your question?

[@goracegoa1808]

My front hubs dosnt have wires coming out of em for electricity but the 4 weel drive kicks in when it needs it. My hubs says (demand 4 drive patent pending) on them. It dose have a grub screw for to add oil but what oil would mine need ? My bike is always spining its rear tires first then the front kicks in by it self . I don't have a buton to activate the 4x4. Haven't seen the same hubs like mine online yet. They all have wires for electricity going to the magnets to engage it. My bike also has no batterie

[@MrFixit1]

​@@goracegoa1808 Interesting. what is the model number on the frame sticker? right side under shifter. Should start with a "W"

[@MrFixit1]

Ok after a bit of research sounds like you have an older 1987-1988 Trail boss 250 4x4. which doesn't use electromagnets in the hubs. You can use ATF type-F or the Polaris demand drive fluid.

[@goracegoa1808]

@@MrFixit1 thank you!!

[@djodjodubois9458]

1000000 THANKS! I AM SO HAPPY THANKS TO YOU..the plans for the trail boss are VERY HARD TO FIND AND ARE PAYING TOO EXPENSIVE for me.. IN RE 10000 THANK YOU

[@MrFixit1]

Wow 1,000,000 thanks! That is a lot of Thanks! And thank you for watching.

[@rondykstra5716]

How would you tell if the hub is worn? I have 3 wd. New clutch. The magnet engages. Front left turns sometimes but very slow and only 1 revolution or 2. I have all 4 tires in the air. Thanks for the great video!

[@MrFixit1]

You should see a groove in the inside of the hub. You could measure the inside diameter of the hub and compare it with a known good one. My manual doesn't give a speck for that. Also check the magnet coil pole gap. must be between 0.002"-0.004". Check the roller cage for damage and that the rollers move freely and return automatically with the spring tension. Check that the CV axel is turning. Check the drive key.

[@Wayne-wu3nl]

Great video have a few questions Could I just run 12 volts through a toggle switch directly to the hub and get around all the wiring under the plastics? I find it bothersome that the chain drive to the front differential spins all the time. Is there a way to get the chain to spin only when I think I might need to use the front diff? Can I just remove the front diff chain so it is only 2 wheel drive or will it in someway damage something ? Can you clean and repack the front hub bearing?

[@MrFixit1]

(Q1) Yes. (Q2) No. (Q3) Yes, no harm will be done (Q4) Front hubs are an oil bath. Polaris demand drive fluid or ATF+4.

[@r.greener5355]

If u could let me know my problem. I can grab the clutch the inside is splin but turns rollers go up down but does not grab hub

[@jonathanwilliams5329]

Any advice would be appreciated. I have a 97 sportsman 400L that I got as "junk" with a 330 magnum and 90s 350L. The 400 I managed to get running it needed head and cylinder work but runs. I haven't gotten a battery for it and just use the pull start. Question- do the 4X4 hubs require a battery to work? for stable voltage.

[@MrFixit1]

Yes, needs a battery. Don't run this without the battery it will blow all the bulbs and over charge the electronics.

[@la_plata3588]

I have the chain driven 4x4 for a parts machine

[@mac_gyver-y2d]

Why is there a need for the reverse override interacting the 4wd system. Could it not stay on all the time the awd button is on?

[@MrFixit1]

So that people that don't know any better not to do a reverse wheeley and get hurt flipping over the handle bars backwards

[@rayjrdibenedetto867]

Good morning. First thank you for the video! I have a 1994 Polaris 4x4L-i went to hang some tree stands and when i took me four wheeler off the truck it shut off-so i ended up starting it with the pull cord-when i was using it and shut it off i went to pull start it again and then the pull cord wouldn’t recoil-ended up using a jump box to start it back up-found out-DONT DO THIS! This blew all my light on my machine and i also ended up replacing pull cord and light bulbs and battery-would have saved myself alot of trouble by replacing battery but i was in the woods-i was told the older machines like mine cant take the jump box and found this out after! Wondering what bulb and how to replace the AWD bulb if you can help me that would be great-thats the only one i did not replace and didnt wanna mess anything up! Learned alot about the bulbs and the machine-took some time but what a pain for a simple mistake on my part! Wish i road more but my machine has LOW miles and had it serviced by a friend a while back! He is busy and trying to fix it myself is all. Again thank you for any advice! Have a good day

[@ComicalFerret]

Polaris 4080872 is the part number for the little bulbs

[@rayjrdibenedetto867]

@@ComicalFerret Thank you

[@MrFixit1]

Replacement bulb for the AWD indicator is; BULB,DEMAND-DRIVE IND. 4030047

[@MrFixit1]

@@ComicalFerret This is the part number for the bulbs in the dash.

[@rayjrdibenedetto867]

@@MrFixit1 Hi. I have replaced all f them thank you. I have to replace the AWD bulb but not sure how to when i took it apart last time- something didn’t look right? Maybe it got warm or something? I don’t remember but any chance you know of a video i can watch and or you can do one? Doesn’t hurt to ask? If not I understand and thank you again for all your help! Have a good night

[@12vcumminslife26]

Question for you not regarding the AWD but you seem to know a lot about this ATV.. I have been watching bout every video u got on this ATV I have a 1995 Polaris sportsman 400.. what would u say is wrong if it will not turn the engine off with the key or with the kill switch.. I had to choke it to kill it .. and my atv is doing this some times and then again some times it will turn off with the kill switch or the key ..

[@MrFixit1]

Ok, so the ignition coil needs to be grounded in order to kill spark. So I would say something in the ground wires. Check behind the head light mounted on the rev-limiter box with a screw is a ground wire. Make sure it is tight and clean, also check the connection panel grounds that they are tight and clean. I would start there. If this doesn't fix the problem, feel free to ask any questions. Hope this helps. Thanks for watching.

[@zToxicCobra911]

Not sure where you’re located but if near by for some chance would you fix mine?? Used to start now won’t.. I drove it down the rd and brought it back and was smoking a lil white smoke from engine, not sure if I burnt the spark plug. Or what I knoticed it was loud and I was missing a spring for the exhaust. But fluids are good

[@MrFixit1]

Sothern Ohio Cincinnati area is where I'm located. Yes I would work on your Polaris.

[@dougkilts2010dk]

Do you know what the torque specs are on the hub?

[@MrFixit1]

This is from the manual. It's a bit complicated It's more of a feel on the hub basically tighten the nut and back it off until the hub rolls with a little bit of drag. 4x4 Models with FlexLoc Nut 1. Torque spindle nut (A) to 400 inch Ibs. more than rolling torque and back nut off 1/2 turn. NOTE: Some 1994 and all 1995 to current models have left hand threads on left spindle. 2. Tighten nut again and read the force it takes to rotate the lock nut (nut rolling torque). NOTE: Rolling torque on FlexLoc nuts should be 75 to 400 inch Ibs. If the rolling torque is less than 75 inch Ibs. the nut should be replaced. To achieve the final torque, add the nut rolling torque plus 100 inch Ibs. Example: Rotating nut torque Plus bearing preload Final nut torque = 125 inch Ibs. = 100 inch Ibs. = 225 inch Ibs. 3. Rotate the hub and front drive axle. Re-torque to the reading recorded in step 2. 4. Some models will have a stake nut. Never re-use a stake nut. Replace with a FlexLoc™ nut. NOTE: A FlexLoc™ nut is shown in the center photo (A).

[@chrisalberts504]

What's it mean when your driving in 4wd and your front tire feels like it binds up and turns your tire and pulls the machine that way lime it's turns but you are going foward not turning?

[@MrFixit1]

Sometimes the Hillard clutch gets stuck, and you have to change gears forward or back to unstick it. If you were backing up in AWD and you switch to forward, and it binds up, switch to REV in 2-wheel drive and goose the throttle and the hub will release. Prety normal to happen every now and then. Try NOT to keep driving in this condition as it could cause damage to the hub or Hillard clutch.

[@chrisalberts504]

@MrFixit1 It actually keeps happening constantly so would you say to replace the hillard and hub?

[@MrFixit1]

@@chrisalberts504 I would take it apart and inspect it for damage clean reassemble and refill with oil before I replaced any parts. It could just be dry and or dirty or assembled wrong or all the above.

[@chrisalberts504]

@MrFixit1 found my issue my hilliard clutch is cracked in half

[@MrFixit1]

@@chrisalberts504 Thanks for letting us know. Hope the hub is alright.

[@r.greener5355]

My 1998 left clutch works but when i put hub on it dont grab hub. The ring sticks to magnet clutch new ring new

[@MrFixit1]

Hub could be worn out.

[@twister8ful]

What if my ETC is bad, and override the rev limit

[@MrFixit1]

Overriding the reverse rev limiter will not affect the electronic throttle control limiter. If that is what you're asking.