That was a pretty good explanation. You added the part where the front wheels could always turn faster just not slower than the rear as kind of an afterthought, when in reality that is really the most important part and is the entire reason the system works the way it does. Basically the rear differential is actually geared slightly higher than the front differential, so even when you have the button on for four wheel drive the fronts are still not engaging, because the front drive shaft is actually trying to turn the front tires slower than the speed the vehicle is moving. When the rear tires lose traction the vehicle slows down or the RPMs go up (which is the same thing as far as this system is concerned), at which point the front drive shaft is trying to turn the front wheels faster than the vehicle is moving which it's not allowed to do because of the rollers as you explained, so suddenly the fronts are being powered. The key takeaway is that the front tires are never allowed to spin slower than the speed the transmission is trying to move the vehicle, but they can always spin faster. It's a great system because even when it's engaged it's still allows the outside tire to go faster in a turn then the inside tire, because the tires are always allowed to go faster than the gears are trying to turn them just not slower. On the other hand it's not a great system because when going down a hill your engine braking is only braking the rear tires, because the fronts are always moving faster than the transmission is trying to spin them.
Good explanation of how it works. The unit is not made by Polaris. It is made by Hilliard Corporation, Elmira NY. The little plate @5:45 that helps make the magic is called the "Armature plate".
I don't see you making a video, Whether his talking ability is not up to your standards or not, American SportWorks seems to think his video is very informative and recommends it to their costumers for repair advise. Great job Nathan, Thanks.
Thank you very much for taking the time to make this video. Super helpful. I love mechanical solutions, very repairable compared to magic that happens with electrons.
I’ve been trying for a long time to find out how this differential works and your explanation and how you are showing how it works really made it simple to understand,. Now I don’t have to think about that anymore 😊 Great job and thanks for the explanation 👍🏻
It’s basically like a sprag clutch system you find these in automatic transmissions as well... an example of that would be in a Chevy turbo 400 where the original sprag clutch was a weak point but once upgraded it was nearly bulletproof. Very nice explanation!
Very cool. I believe that other Polaris models have a similar system but they are located independently in each front wheel hub rather than in the differential.
Thank you for making the video to share with us. It's difficult at best to explain a complex set of functions in a short time. You have done a very nice job. We all benefit from it.
That makes more sense as to why it locks up sometimes when you push the button to take it out. And why you need to reverse a little sometimes after. Good explanation.
Thanks! I just bought a used Sportsman 500, and this is some info I was definitely looking for. I wondered why the shaft going to the front spun, even when I had the switch on 2wd.
Very nice! Similar to a fishing reel with an anti reverse. I also have a few ratchets that work on the same principle. Seriously, thanks for sharing this. Without it, I wouldn't have known how it worked.
One thing that you left out that is crucial to the operation is that the front gear is a different ratio than the rear. With the front locked in and all four spinning, the rear tires will turn 5 times and the fronts 4 times.
Great video. I dismantled our diff for new bearings and like you i wanted to know how it worked. I would never have worked that it in a month of Sundays.
that's a really cool explanation! i thought it had sensors but now i know differently. thanks for raking the time to show us how that diff really works!
There is definitely power to the front in 4wd, my 2006 scrambler had a bad chain so I was replacing it but had to wait a few days and I was able to ride it in 4wd using only the fronts to pull me along. So it definitely does get power to the front on its own, I did however notice in sloppy conditions the front tires can actually spin a bit faster on occasion than the back tires. I've been looking into this 4x4 setup as I'm trying to learn how I can make a 4x4 race quad, using some Polaris parts.
Wow great video thanks for the explanation I have the same machine so I'm learning a lot you are very smart and I appreciate the delivery of this video you explained it very well you are a great help thank you
Hey man excellent job and I appreciate you takin out of your own time to make that video keep up the good work dude. Oh BTW I rarely ever (EVER) leave a comment But dont"t stop shining bro Light It up out there.
I think the sensors you hear about are in the active descent control system, and the speed sensor deactivate system. In any case, this system has a lot of faults. The biggest two are that you can't lock the wheels in permanently, and engine braking can't be sent to the front tires unless a separate system (adc) is added. Also, if you want all four tires to pull you up a steep hill that has good traction (like a sandstone obstacle in Moab), this awd system will never engage because the rear tires won't spin faster than the fronts. So you are essentially forced to just have the rear 2 tires pushing only. If you really want 4wd, you have to get a Kawasaki, Yamaha, Suzuki, Arctic Cat, or newer Honda.
I can tell you that if you're going up a hill and your back wheels are not spinning you don't need 4WD- The second the back tires spin even a tiny bit; the fronts will be engaged. You won't feel it engage but look out the front of the door they are engaged & grabbing. If you have enough traction to make it up the hill without spinning no. BUT if then you floor it so the back spins the fronts will immediately start digging! Leave it in 4WD in sand and you will have it. If you want to fart around and just spin shitties just leave the switch off.
this really helps, but what i'm also trying to figure out is, do thos plates with tabs on it wear out like clutches are they spining on each other? and can thos rollers spin and also wear out or is there no parts in there that will wear out othere then the main 3 bearings and gears?
Great video, i understand how this system works a little more now, but can anyone explain why my front diff engages when switch is in 2 WD, and the rear wheels are spinning in snow? could it be worn front diff parts causing it to engage without the coil being activated?
My 2000 polaris scrambler 500 is slightly different. Still functions similarly but not exactly the same. It has a front differential "gear box" that is centered between the front wheels. That has a shaft out each side that connects to the CV axel, which connects to the "Hillard clutch" that is located inside the wheel hub assembly. There is some sort of "slip differential" to the system when you are in 2WD. When you are in 2WD and stuck in mud, the front wheel(s) will engage automatically. When you move the selector to "AWD" it will in fact give power to the front and rear wheels at all time. I believe that just one of the front wheels engage at a time but I'm not sure...it my be both. Another way I have seen this work is when the chain popped off the sprocket on the rear wheels. When it did this, the quad was still driving by using the front wheels only, and this was when it's in 2WD. There is nothing broken with it, this is how it work. I saw others comment on seeing just 1 front wheel spin in a video and were concerned there were issues...that's not the case. The person in the video just had it in 2WD and the rear wheels were spinning. The AWD selector locks the front and rear together whether you are spinning or not. I love the system. There really is never any need to set it to AWD, as the quad automatically sends power to the front when needed.
Appreciate the explanation, but, I can't figure out whats wrong with my on damand AWD still yet. My 05 Polaris Sportsman 500 H.O. has this 4WD style system, the dash pod lights up with the 4wd indicator, but, the rear tires will spin, sometimes up to 25/30 mph before the front tires will engage, and when it happens it's violent. I was stuck yesterday, pushed the "4wd" button, in forward Lo, and gradually gave it gas, front tires didn't pull. So I increased throttle and they finally came in and pulled. Not sure what to do to correct this? Any input is appreciated sir. Thanks
great video, i was having issues with mine going in, was a grounding issue now it will not come out of 4x4. Why would it be stuck in 4x4 if mag is energized? Any ideas?
Just asking there is a clip kind of c shaped. Trying to figure out where this little piece goes. It has a slight curve to it like it snaps in somewhere. I looks like the piece you have on the table its flat and curves down on the ends. I dont know where it goes. I have all my parts and ready to put it back together but want to make sure everything goes where it suppose to. Any help would be great.
My bike sounds like it's missing a gear in 2wd or it's lost bearing, but when I click the switch in to 4wheel drive system on its not as bad ....how do I find this problem its sounds like its the front but not sure ....help me plz!! Thank you in advance !!
Great video! I have a 2014 Sportsman 550 X2 the issue I am having is my 550 has no 4-wheel drive while going forward but as soon as I go in reverse 4 wheel drive works. I saw this video and was hoping i can figure out what's going on, if anyone can help me with this issue it would be greatly appreciated.
Are both front tires suppose to engage when I turn on the AWD switch automatically or is it by weight distribution? I am asking because I feel that my front left tire is not engaging as much as my front right tire.
Fantastic explanation. The wires that come out of my front diff are MISSING, almost like someone ripped them out. The model # is 1341344. Can't find the part anywhere ! Anybody have suggestions ?
Also from watching another video. It disengages because the rear wheels spin slightly faster then the front wheels. So that's how it disengages ones you get unstuck. There is a bid of one strapped and on ice. The wheels have a white rah tide to a spoke on each wheel. When he makes the wheels spins ever so slow you can clearly see that that rear wheel spins slightly faster then the front. So once stuck the front hub grabs because the wheels aren't moving and when the back can propel on its own it pushes the front unlocked.
I have a polar sportsman H.O. EFI model 2008 and I found that in reverse it does not engage the face! What would be the cause? and sometimes it stops at idle when the engine is hot!
Does anyone knows how much meter of wire is going into the magnet of the asm cover plate. Because mine AWD line has been broken inside in the side cover plate and the only way was to open the magnet . After then I have done that the line in the magnet ( selenoid has been broken) .
Thank you for this video. I’m about to take on a project with my sportsman 500 HO. My issue is, it seems that my front wheel, hub, brake, something is causing my front right to drag and lock up on me, pulling me to the right. I can fight it and force it left sometimes. Other times, I can pop a wheelie and it will free up the bind. I’m not sure what’s on the inside of this unit that could be giving me this problem. So your video will definitely help. 👍🙏
I have a very similar issue with my 500 xplorer, except its my left front hanging up causing it to push right, i think its all in my hub assembly also but the parts haven't cone in yet, would love to here if you got it fixed and what was wrong
Kyle Maples, so when I took the wheel off the hub, the assembly was all rusted and seized. For several days I sprayed it with penetrating fluid, mystery oil, atf, and beat on it. It finally broke free an I disassembled the hub and removed the axle assembly from the hub. I soaked all the parts that were in the hub for another day, in mystery oil. Old tooth brush and a rag, scrubbed everything really well. Cleaned up great. Whipped it all dry and reassembled, put atf in hub and drove around. All works great on the right side now. Seals leak, so I’ll replace those soon, before I go ride of course. Feels like my left side is dragging too, so I’ll repeat the process and order inner and outer seals for both sides. Taking everything apart and cleaning seemed to do the trick though. There is another video I watched as well. He’s in Alaska. Great information 👍
@@jasonkeith674 cool thanks, that makes me think I'm right about mine, ordered a whole hub rebuild kit with new bearings, races, clutch, and seal. When I took mine apart there was no fluid just sludgey rust with alot of metal shaving, should be getting the parts today and going to put them in this weekend, thanks for the reply
Kyle Maples good deal man. I bought a new axle assembly before tearing into it. Not knowing any better of course. Turns out for the right side I just need seals. It was dry when I popped the cap. Hopefully left side just needs cleaning. It was full of fluid when I popped the cap. Just grungy. I ordered my axle from East Lake Axle. I’ll probably get my seals and some just in case bearings as well. I’m still trying to remember the Alaska guy’s name. He has great videos
2015 XP 900 Ranger. I have power to hot side of plug from switch and also have ground. Ground completes circuit when switched to 4x4. Insulation is pulled back from side of case exposing copper braid at side case penetration from weeds wrapping around axle. 4X4 won't engage. Please advise!
Thank you for the explanation. Someone told me that the rzr s900 does not have a rear wheel diferenchal. Only a front one. This looks to me like its the opposite. In a 4x4 truck. They have both. Can you go into more detail for me please?
I can't speak to the operation of the RZR, but as someone else has pointed out in the comments, this unit is not really a differential. A differential is a gearbox that allows a driveshaft to drive both wheels, but at different speeds independently of each other. When it's engaged, this gearbox locks the front two wheels together, so there is no "differential" action. I would imagine the drive train is similar on the RZR, but I don't have enough experience to tell you for sure how that one works.
The rollers in the cage will turn just a bit to wedge against the output drive splines. In other words, the round rollers wedge hard, steel to steel 'over center', once over center they will drive the 2 splined outputs. Think leverage! The rollers have leverage when the magnet is on. Works the same in reverse.
I don’t have any comments but I do have a question. My question is this. What do you think of the AWD system? Basically how strong is that magnet? Does it slip when under load
So for the people who just leave it on, does that actuator plate wear down quicker? Isn't it dragging on the housing/magnet whenever the system is on? Or, does it not touch it, just very close to the magnet?
Nice how much would u or a mechanic charge for something like this I think my Polaris needs a differential just had one mechanic look at it he said something like mind is not building enough pressure to engage the front
Thank you Nathan ...great video ! I understand now how it works 4WD from my Polaris 500 EFI Sportsman . But i have a question for you ! It is not very clear for me when this mecahanism is engaged the another shaft side is blocked ? Or is free ...? I mean we have all front wheel drive simultanesly or is a kind of diferential ? Thank you
If I understand your question, you are asking if there is a differential action between the two front wheels, and the answer to that is no. When the on-demand 4x4 kicks in, the two front wheels are locked together.
@@thenathans96 Thank you Nathan ... . It is perfectly , Nice job .I have another question (escuse me again ). If i lift up the front body of ATV with the weel up (free of terain ) and i push the 4x4 button what is happening ? I can see if this PLATE ARMATURE mechanism is working ? I supose not ...it the main shaft wich come of the engine is stopped (is not running) ! How is the most simple way to make a test for i see my front wheel is locked ! Please give me a suggestion ! Best regards - Marius from Romania !
@@mapo130 In order to test the system this way, you'd have to have all 4 wheels off the ground so that the back wheels can turn freely and you can see if the front wheels turn when you engage the system by pushing the button. Running the ATV like that would be dangerous though, and I don't recommend it. A good real-world test would be to get stuck in a giant mud puddle and see if all 4 wheels turn or just the back ones.
@@thenathans96 I understand all the story ...yes that.s right it is dangerous ..to make the test with the rear train in air (up) . I will make the test in the snow ...it is better and safely ! Thank you for quickly reply . I wish you a good day . With respect ...Marius !
Mine won’t engage, is that my lack of ADC fluid or would that have to do with the magnet not engaging. The light does not even turn on on the dash when I flip the switch.
does the Sportman Touring 570 have REAR differential ? I tested but it seems no such thing there, it' s just a basic gear, both wheels spinning same RPM no matter AWD / 4x2 selected .. ...! dissapointing ...
I need to change axle splines. In side differential. Any thing special I need to do to be able to pull them out of roller cage other than split case open ?
Great explanation, is there a way to permanently lock it up to make vehicle full time 4-wheel drive, would there be a reason not to have it locked in permanently Thanks
This is a DEMAND drive. It will never lock FULL TIME. If you want a full time 4x4 system, you need to get a different machine or replace the front end.
farnsmark I'm not 💯 percent sure but I have a front different out of a 500 sportsman HO that does not have any wires to it and it's always locked. It looks like the 500 HO locks at the wheel hubs instead. If you interchanged the two front diffs you would have all the time 4x4.
I haven't done a lot of work on them, I just made the video explaining how it works. But I would check the electrical parts first. Should be a wire running into the side of the front differential, make sure nothing's shorting out and the switch is engaging.
I've seen a few times online that a ground issue going to the coil. Find the ground (-) and test if it has continuity to the frame. If not tap a ground to that wire.
very good video but how can this work when you are in reverse? I'm thinking the plate turning is not what happens but each of the 14 rollers is magnetized or repelled away from the carrier onto the center shaft.. The 14 notches get shallower at each end forcing the rollers to lock onto the shaft. Centrifugal force would keep the rollers disengaged when no current is applied. Again , Thanks for making this video and maybe that is what you are saying but I did not get it.
There is no engagement in reverse or going down a hill. You will not have front wheels engaged in either case. Its basically a sprag, or a one way type thing, only locks up going forward.
Does anyone know if this is the same general concept used in the Polaris Rangers? Mine will go into AWD on its own occasionally, and I have to drive it backwards to get it back into rear wheel drive.
so when the rollers "clamp down" on the "splined side pieces" of front half shaft isn't there a chance of those rollers slipping/rolling on those side pieces like cylindrical ball bearings ??
Maybe under some unique circumstance (maybe incorrect fluid in the transfer case?), but I can't imagine that ever happening if the magnetic part engages properly.
Its a sprag. The rollers get bound up between the outer case and the barrel they are in. They get pinched tight so they cant be moved. The inside surface of the carrier is angled in on the one side, as the inner barrel is twisted back by the resistance from the magnet, the space gets smaller, hence tighter until it binds up.
Happy Thanksgiving! I'd probably change the fluid and make sure its replaced with the correct stuff, and the gearbox is cleaned thoroughly inside. You can find that info online but it's very important that it's the Polaris recommended fluid.
My 2005 700 polaris sportsman got stuck today. I accelerated rear wheels spinning AWD locked in for a brief second with a loud clunk then no AWD any more in forward but was engaging in reverse when I parked it in my garage. Any idea what could be wrong?
Sorry, I can't think how you'd know without pulling it apart to see what's broken. Possible something snapped in the front gear box but you'd have to dig in to know what. The plastic carrier thingy is about the only breakable part in there, but it shouldn't really be stressed under load. Sorry
@@armedfarm3429 I found issue. The plastic roller cage had a small piece broken out of it and it was preventing it from rolling to lock. I cleaned out gear flipped over the cage reinstalled and works fine. Ordered a new aluminum one and swapped out. Part was 5 weeks out I shot from the hip hoping it would work and it got me enough time.
That was a pretty good explanation. You added the part where the front wheels could always turn faster just not slower than the rear as kind of an afterthought, when in reality that is really the most important part and is the entire reason the system works the way it does. Basically the rear differential is actually geared slightly higher than the front differential, so even when you have the button on for four wheel drive the fronts are still not engaging, because the front drive shaft is actually trying to turn the front tires slower than the speed the vehicle is moving. When the rear tires lose traction the vehicle slows down or the RPMs go up (which is the same thing as far as this system is concerned), at which point the front drive shaft is trying to turn the front wheels faster than the vehicle is moving which it's not allowed to do because of the rollers as you explained, so suddenly the fronts are being powered.
The key takeaway is that the front tires are never allowed to spin slower than the speed the transmission is trying to move the vehicle, but they can always spin faster.
It's a great system because even when it's engaged it's still allows the outside tire to go faster in a turn then the inside tire, because the tires are always allowed to go faster than the gears are trying to turn them just not slower.
On the other hand it's not a great system because when going down a hill your engine braking is only braking the rear tires, because the fronts are always moving faster than the transmission is trying to spin them.
agree with you,what can cause the front wheel to lock up?even this differential broke, it will not lock the front wheel, but drive the front wheel
Also people get in trouble buying tires of different heights, then can't figure out why 4wd don't work right.
6 years later this is still the best video to explain how it works
60 years from now he will be a ble to retire rich on royalties from Utube!
Nice job explaining how this works. I enjoy people who take the time to figure out how things work and then help others to understand.
Good explanation of how it works. The unit is not made by Polaris. It is made by Hilliard Corporation, Elmira NY. The little plate @5:45 that helps make the magic is called the "Armature plate".
I don't see you making a video, Whether his talking ability is not up to your standards or not, American SportWorks seems to think his video is very informative and recommends it to their costumers for repair advise. Great job Nathan, Thanks.
Thank you very much for taking the time to make this video. Super helpful. I love mechanical solutions, very repairable compared to magic that happens with electrons.
3 years later your information is still helping people
I’ve been trying for a long time to find out how this differential works and your explanation and how you are showing how it works really made it simple to understand,.
Now I don’t have to think about that anymore 😊
Great job and thanks for the explanation 👍🏻
It’s basically like a sprag clutch system you find these in automatic transmissions as well... an example of that would be in a Chevy turbo 400 where the original sprag clutch was a weak point but once upgraded it was nearly bulletproof. Very nice explanation!
Awesome demo, the best explanation I've found on how these Polaris AWD systems work, thanks.
Very cool. I believe that other Polaris models have a similar system but they are located independently in each front wheel hub rather than in the differential.
A little long but if paying attention, it comes to ya. Good job. You helped a lot of people understand it.
Thank you for making the video to share with us. It's difficult at best to explain a complex set of functions in a short time. You have done a very nice job. We all benefit from it.
That makes more sense as to why it locks up sometimes when you push the button to take it out. And why you need to reverse a little sometimes after. Good explanation.
Thanks! I just bought a used Sportsman 500, and this is some info I was definitely looking for. I wondered why the shaft going to the front spun, even when I had the switch on 2wd.
I think you did a good job of explaining the function of the Polaris Demand Drive and I already knew how it worked. It made sense to me. Thanks.
Very nice! Similar to a fishing reel with an anti reverse. I also have a few ratchets that work on the same principle.
Seriously, thanks for sharing this. Without it, I wouldn't have known how it worked.
One thing that you left out that is crucial to the operation is that the front gear is a different ratio than the rear. With the front locked in and all four spinning, the rear tires will turn 5 times and the fronts 4 times.
YOU are a superstar. If you’re passing Oxfordshire, UK: I owe you a drink. 👍🏻
Thanks a lot for the knowledge that you have provided. I was curious how on demand differential work. Now I know.
Great video. I dismantled our diff for new bearings and like you i wanted to know how it worked. I would never have worked that it in a month of Sundays.
Thank you thank you. Couldn’t find anyone including my mechanic friends who could explain this to me.
that's a really cool explanation! i thought it had sensors but now i know differently. thanks for raking the time to show us how that diff really works!
I have a lot better knowledge of how this works now. Hands on is the best way to explain how things work. Thanks
Very Good! I was wondering how my AWD was locked in with the switch off. Now I know where to start looking. Thank you.
Thanks, i was wondering if the ring and pinion turned when i was in two wheel drive.
There is definitely power to the front in 4wd, my 2006 scrambler had a bad chain so I was replacing it but had to wait a few days and I was able to ride it in 4wd using only the fronts to pull me along. So it definitely does get power to the front on its own, I did however notice in sloppy conditions the front tires can actually spin a bit faster on occasion than the back tires. I've been looking into this 4x4 setup as I'm trying to learn how I can make a 4x4 race quad, using some Polaris parts.
Wow great video thanks for the explanation I have the same machine so I'm learning a lot you are very smart and I appreciate the delivery of this video you explained it very well you are a great help thank you
Hey man excellent job and I appreciate you takin out of your own time to make that video keep up the good work dude. Oh BTW I rarely ever (EVER) leave a comment But dont"t stop shining bro Light It up out there.
I think the sensors you hear about are in the active descent control system, and the speed sensor deactivate system.
In any case, this system has a lot of faults. The biggest two are that you can't lock the wheels in permanently, and engine braking can't be sent to the front tires unless a separate system (adc) is added.
Also, if you want all four tires to pull you up a steep hill that has good traction (like a sandstone obstacle in Moab), this awd system will never engage because the rear tires won't spin faster than the fronts. So you are essentially forced to just have the rear 2 tires pushing only.
If you really want 4wd, you have to get a Kawasaki, Yamaha, Suzuki, Arctic Cat, or newer Honda.
I can tell you that if you're going up a hill and your back wheels are not spinning you don't need 4WD-
The second the back tires spin even a tiny bit; the fronts will be engaged. You won't feel it engage but look out the front of the door they are engaged & grabbing. If you have enough traction to make it up the hill without spinning no. BUT if then you floor it so the back spins the fronts will immediately start digging! Leave it in 4WD in sand and you will have it. If you want to fart around and just spin shitties just leave the switch off.
Suzuki king quad 750. Good wheeler. I’ve had a few Polaris & they worked well but there are to many times that the diff lock is needed
Great explanation! Thanks for showing us how this works!!
Great video man! Excellent explanation of how the front diff works!
Great video explaining how it works. Good job😊
this really helps, but what i'm also trying to figure out is, do thos plates with tabs on it wear out like clutches are they spining on each other? and can thos rollers spin and also wear out or is there no parts in there that will wear out othere then the main 3 bearings and gears?
Great video, i understand how this system works a little more now, but can anyone explain why my front diff engages when switch is in 2 WD, and the rear wheels are spinning in snow? could it be worn front diff parts causing it to engage without the coil being activated?
this is a great video... thank you for taking the time my man. I appreciate it.
Thank you so much. I greatly appreciate the info since I am a newbie to this polaris rzr world. Great job.
Great job. That cleared up some confusion on my part as to how that really works.
Hello, good video explanation, question if in dash ligths on the 4wd it means working? Or it can be ider not working
My 2000 polaris scrambler 500 is slightly different. Still functions similarly but not exactly the same. It has a front differential "gear box" that is centered between the front wheels. That has a shaft out each side that connects to the CV axel, which connects to the "Hillard clutch" that is located inside the wheel hub assembly. There is some sort of "slip differential" to the system when you are in 2WD. When you are in 2WD and stuck in mud, the front wheel(s) will engage automatically. When you move the selector to "AWD" it will in fact give power to the front and rear wheels at all time. I believe that just one of the front wheels engage at a time but I'm not sure...it my be both.
Another way I have seen this work is when the chain popped off the sprocket on the rear wheels. When it did this, the quad was still driving by using the front wheels only, and this was when it's in 2WD. There is nothing broken with it, this is how it work. I saw others comment on seeing just 1 front wheel spin in a video and were concerned there were issues...that's not the case. The person in the video just had it in 2WD and the rear wheels were spinning. The AWD selector locks the front and rear together whether you are spinning or not. I love the system. There really is never any need to set it to AWD, as the quad automatically sends power to the front when needed.
Appreciate the explanation, but, I can't figure out whats wrong with my on damand AWD still yet. My 05 Polaris Sportsman 500 H.O. has this 4WD style system, the dash pod lights up with the 4wd indicator, but, the rear tires will spin, sometimes up to 25/30 mph before the front tires will engage, and when it happens it's violent. I was stuck yesterday, pushed the "4wd" button, in forward Lo, and gradually gave it gas, front tires didn't pull. So I increased throttle and they finally came in and pulled. Not sure what to do to correct this? Any input is appreciated sir. Thanks
Hello did You find the solution? I have that problem but My does not emgage
what is the set screw that has a magnet on it for and how do you adjust it
Good vid!
Sounds like it works the same way as a one way starter clutch.
nice vid, its a sprag that has an interesting way of being activated. pretty cool.
Very good explanation of an extremely complex system.
great video, i was having issues with mine going in, was a grounding issue now it will not come out of 4x4. Why would it be stuck in 4x4 if mag is energized? Any ideas?
I’m currently having the same issue
Have you find the problem ? I have the same probleme.
Same issues, fix for this??
Also having the same issue.
Just asking there is a clip kind of c shaped. Trying to figure out where this little piece goes. It has a slight curve to it like it snaps in somewhere. I looks like the piece you have on the table its flat and curves down on the ends. I dont know where it goes. I have all my parts and ready to put it back together but want to make sure everything goes where it suppose to. Any help would be great.
Yup- good explanation. surprisingly simple system but obviously very effective- Thank You!!
So if 1 tires spins but the other one don't is that a broken magnetic plate is the 2 of them plates one for each side
My bike sounds like it's missing a gear in 2wd or it's lost bearing, but when I click the switch in to 4wheel drive system on its not as bad ....how do I find this problem its sounds like its the front but not sure ....help me plz!! Thank you in advance !!
Great video! I have a 2014 Sportsman 550 X2 the issue I am having is my 550 has no 4-wheel drive while going forward but as soon as I go in reverse 4 wheel drive works. I saw this video and was hoping i can figure out what's going on, if anyone can help me with this issue it would be greatly appreciated.
Good job on the video explaining the workings.
Well done, sir. Thank you. Couldn't find this information anywhere else. I'm assuming they carried a similar system into the new RZRs.
FREAKIN' EXCELLENT! Best explanation I've ever heard. Thank you!
Love this video! Thank you for explaining
Are both front tires suppose to engage when I turn on the AWD switch automatically or is it by weight distribution? I am asking because I feel that my front left tire is not engaging as much as my front right tire.
Fantastic explanation. The wires that come out of my front diff are MISSING, almost like someone ripped them out. The model # is 1341344. Can't find the part anywhere ! Anybody have suggestions ?
This video has aged well. Thanks for sharing.
Great explanation. I love how ppl have smart A$$ comments but apparently do not understand how the system works, Hence they are watching your video.
So, how could one make this so I get the same power to the front as I do in the back?
Video helped out a bunch also I can't find how tight supposed to adjust the screw for the plate that goes up against the diff gear any idea on that?
Good job brother!!!!!!! You explained it perfectly
That’s incredible engineering
Also from watching another video. It disengages because the rear wheels spin slightly faster then the front wheels. So that's how it disengages ones you get unstuck. There is a bid of one strapped and on ice. The wheels have a white rah tide to a spoke on each wheel. When he makes the wheels spins ever so slow you can clearly see that that rear wheel spins slightly faster then the front. So once stuck the front hub grabs because the wheels aren't moving and when the back can propel on its own it pushes the front unlocked.
Jerome Ponder well said 👍
How can you get it to be like a atv . I want it to engage when I tell it to , not when the tires slip
this video was really helpful and and very well explained thanks!
Nice! I like this AWD system. It looks strong.
I have a polar sportsman H.O. EFI model 2008 and I found that in reverse it does not engage the face! What would be the cause? and sometimes it stops at idle when the engine is hot!
Sportsman models are DIFFERENT. They don't run of a centralized differential
thanks. that puts to words and demonstration what i was thinking might be happening. good job
Does anyone knows how much meter of wire is going into the magnet of the asm cover plate. Because mine AWD line has been broken inside in the side cover plate and the only way was to open the magnet . After then I have done that the line in the magnet ( selenoid has been broken) .
Nice thorough explaining 👍
Thank you for this video. I’m about to take on a project with my sportsman 500 HO.
My issue is, it seems that my front wheel, hub, brake, something is causing my front right to drag and lock up on me, pulling me to the right. I can fight it and force it left sometimes. Other times, I can pop a wheelie and it will free up the bind. I’m not sure what’s on the inside of this unit that could be giving me this problem. So your video will definitely help. 👍🙏
I have a very similar issue with my 500 xplorer, except its my left front hanging up causing it to push right, i think its all in my hub assembly also but the parts haven't cone in yet, would love to here if you got it fixed and what was wrong
Kyle Maples, so when I took the wheel off the hub, the assembly was all rusted and seized. For several days I sprayed it with penetrating fluid, mystery oil, atf, and beat on it. It finally broke free an I disassembled the hub and removed the axle assembly from the hub. I soaked all the parts that were in the hub for another day, in mystery oil. Old tooth brush and a rag, scrubbed everything really well. Cleaned up great. Whipped it all dry and reassembled, put atf in hub and drove around. All works great on the right side now. Seals leak, so I’ll replace those soon, before I go ride of course. Feels like my left side is dragging too, so I’ll repeat the process and order inner and outer seals for both sides. Taking everything apart and cleaning seemed to do the trick though. There is another video I watched as well. He’s in Alaska. Great information 👍
@@jasonkeith674 cool thanks, that makes me think I'm right about mine, ordered a whole hub rebuild kit with new bearings, races, clutch, and seal. When I took mine apart there was no fluid just sludgey rust with alot of metal shaving, should be getting the parts today and going to put them in this weekend, thanks for the reply
Kyle Maples good deal man. I bought a new axle assembly before tearing into it. Not knowing any better of course. Turns out for the right side I just need seals. It was dry when I popped the cap. Hopefully left side just needs cleaning. It was full of fluid when I popped the cap. Just grungy. I ordered my axle from East Lake Axle. I’ll probably get my seals and some just in case bearings as well. I’m still trying to remember the Alaska guy’s name. He has great videos
Kyle Maples look up, Erik in Alaska. 👍👍
Your mind works like mine. I got it. Wonder explanation, thanks.
Great video! My spline had some play in it... Digging in this weekend
2015 XP 900 Ranger. I have power to hot side of plug from switch and also have ground. Ground completes circuit when switched to 4x4. Insulation is pulled back from side of case exposing copper braid at side case penetration from weeds wrapping around axle. 4X4 won't engage. Please advise!
The "4x4" isn't really driving all four wheels until the back wheels are spinning. How do you know it's not working?
Thank you for the explanation. Someone told me that the rzr s900 does not have a rear wheel diferenchal. Only a front one. This looks to me like its the opposite. In a 4x4 truck. They have both. Can you go into more detail for me please?
I can't speak to the operation of the RZR, but as someone else has pointed out in the comments, this unit is not really a differential. A differential is a gearbox that allows a driveshaft to drive both wheels, but at different speeds independently of each other. When it's engaged, this gearbox locks the front two wheels together, so there is no "differential" action. I would imagine the drive train is similar on the RZR, but I don't have enough experience to tell you for sure how that one works.
what can cause the front wheel to lock up?even this differential broke, it will not lock the front wheel, but drive the front wheel
The rollers in the cage will turn just a bit to wedge against the output drive splines. In other words, the round rollers wedge hard, steel to steel 'over center', once over center they will drive the 2 splined outputs.
Think leverage! The rollers have leverage when the magnet is on. Works the same in reverse.
Wow. You made that make total sense. Thank you so much!
It’s like an actuated one way bearing, kind of. Very helpful video, thanks.
So does it work in reverse as well?
I don’t have any comments but I do have a question. My question is this. What do you think of the AWD system? Basically how strong is that magnet? Does it slip when under load
So for the people who just leave it on, does that actuator plate wear down quicker? Isn't it dragging on the housing/magnet whenever the system is on? Or, does it not touch it, just very close to the magnet?
I don't think there's anything keeping it from touching so yeah I wouldn't just drive around with it on.
Nice how much would u or a mechanic charge for something like this I think my Polaris needs a differential just had one mechanic look at it he said something like mind is not building enough pressure to engage the front
Thank you Nathan ...great video ! I understand now how it works 4WD from my Polaris 500 EFI Sportsman . But i have a question for you ! It is not very clear for me when this mecahanism is engaged the another shaft side is blocked ? Or is free ...? I mean we have all front wheel drive simultanesly or is a kind of diferential ?
Thank you
If I understand your question, you are asking if there is a differential action between the two front wheels, and the answer to that is no. When the on-demand 4x4 kicks in, the two front wheels are locked together.
@@thenathans96 Thank you Nathan ... . It is perfectly , Nice job .I have another question (escuse me again ). If i lift up the front body of ATV with the weel up (free of terain ) and i push the 4x4 button what is happening ? I can see if this PLATE ARMATURE mechanism is working ? I supose not ...it the main shaft wich come of the engine is stopped (is not running) !
How is the most simple way to make a test for i see my front wheel is locked ! Please give me a suggestion !
Best regards - Marius from Romania !
@@mapo130 In order to test the system this way, you'd have to have all 4 wheels off the ground so that the back wheels can turn freely and you can see if the front wheels turn when you engage the system by pushing the button. Running the ATV like that would be dangerous though, and I don't recommend it. A good real-world test would be to get stuck in a giant mud puddle and see if all 4 wheels turn or just the back ones.
@@thenathans96 I understand all the story ...yes that.s right it is dangerous ..to make the test with the rear train in air (up) . I will make the test in the snow ...it is better and safely !
Thank you for quickly reply .
I wish you a good day . With respect ...Marius !
@@mapo130 Yep
Mine won’t engage, is that my lack of ADC fluid or would that have to do with the magnet not engaging. The light does not even turn on on the dash when I flip the switch.
I'd look for an electrical problem if the light isn't working. Bad or low fluid might make it not engage, but I think the light would still work
does the Sportman Touring 570 have REAR differential ? I tested but it seems no such thing there, it' s just a basic gear, both wheels spinning same RPM no matter AWD / 4x2 selected .. ...! dissapointing ...
Wow. Good info. That’s a very ingenious system.
What vehicle is this diff out of year model
I need to change axle splines. In side differential. Any thing special I need to do to be able to pull them out of roller cage other than split case open ?
Great explanation, is there a way to permanently lock it up to make vehicle full time 4-wheel drive, would there be a reason not to have it locked in permanently
Thanks
This is a DEMAND drive. It will never lock FULL TIME. If you want a full time 4x4 system, you need to get a different machine or replace the front end.
Pull it apart, weld the three pieces together. But you wouldn't be able to steer it on hard ground because you'd have no front differential action
farnsmark I'm not 💯 percent sure but I have a front different out of a 500 sportsman HO that does not have any wires to it and it's always locked. It looks like the 500 HO locks at the wheel hubs instead. If you interchanged the two front diffs you would have all the time 4x4.
Polaris moved the location of the On Demand system (Hillard clutch) from the front hubs to the front diff, around 2004
Paul Mccallum thanks for the info.
I just went to plow snow today and my AWD wouldn’t engage. Where should I start looking for the problem?
I haven't done a lot of work on them, I just made the video explaining how it works. But I would check the electrical parts first. Should be a wire running into the side of the front differential, make sure nothing's shorting out and the switch is engaging.
I've seen a few times online that a ground issue going to the coil. Find the ground (-) and test if it has continuity to the frame. If not tap a ground to that wire.
very good video but how can this work when you are in reverse? I'm thinking the plate turning is not what happens but each of the 14 rollers is magnetized or repelled away from the carrier onto the center shaft.. The 14 notches get shallower at each end forcing the rollers to lock onto the shaft. Centrifugal force would keep the rollers disengaged when no current is applied. Again , Thanks for making this video and maybe that is what you are saying but I did not get it.
There is no engagement in reverse or going down a hill. You will not have front wheels engaged in either case. Its basically a sprag, or a one way type thing, only locks up going forward.
@@ghostcirice8646 Front wheels on my ranger will spin in reverse. I would be stuck in mud often if this wasn't the case.
Does anyone know if this is the same general concept used in the Polaris Rangers? Mine will go into AWD on its own occasionally, and I have to drive it backwards to get it back into rear wheel drive.
This is how all of polaris's four wheel drive vehicles work.
so when the rollers "clamp down" on the "splined side pieces" of front half shaft isn't there a chance of those rollers slipping/rolling on those side pieces like cylindrical ball bearings ??
Maybe under some unique circumstance (maybe incorrect fluid in the transfer case?), but I can't imagine that ever happening if the magnetic part engages properly.
@@thenathans96 hmm... guess it comes down to precision engineering. Especially for the rollers and cage.
Its a sprag. The rollers get bound up between the outer case and the barrel they are in. They get pinched tight so they cant be moved. The inside surface of the carrier is angled in on the one side, as the inner barrel is twisted back by the resistance from the magnet, the space gets smaller, hence tighter until it binds up.
I have a 2004 Polaris sportsman 500 On demand AWD and it is staying in AWD all the time any advice
Happy Thanksgiving! I'd probably change the fluid and make sure its replaced with the correct stuff, and the gearbox is cleaned thoroughly inside. You can find that info online but it's very important that it's the Polaris recommended fluid.
That for a 2003 polaris 500?
My 2005 700 polaris sportsman got stuck today. I accelerated rear wheels spinning AWD locked in for a brief second with a loud clunk then no AWD any more in forward but was engaging in reverse when I parked it in my garage. Any idea what could be wrong?
Sorry, I can't think how you'd know without pulling it apart to see what's broken. Possible something snapped in the front gear box but you'd have to dig in to know what. The plastic carrier thingy is about the only breakable part in there, but it shouldn't really be stressed under load. Sorry
Right kind of fluid in the diff??? It can't be anything like mtr oil or the rollers won't wedge, I like type F or CVT.
@@armedfarm3429 I found issue. The plastic roller cage had a small piece broken out of it and it was preventing it from rolling to lock. I cleaned out gear flipped over the cage reinstalled and works fine. Ordered a new aluminum one and swapped out. Part was 5 weeks out I shot from the hip hoping it would work and it got me enough time.
Excellent explanation. Thank you.
That was great information i was always wondering how that engaged.. thanks
Well well explained in my opinion.