Leaderboard

Doh.. I'm an idiot.. The DCT is in another forum.. I really must pay more attention.. This bike is a five speed with an electric shift, and the usual centrifugal clutch and a plate clutch for shifting..

Hit clear editor and it will go away then you can type in your new post, been happening to me also. I also didnt get new notifications for a few days but seems to be working right now. Really appreciate the Admin for keeping this site running good.

Here's a suggestion for pulling a stuck axle out of a diff. I use a regular 6' tiedown that I wrap one end around the axle & the other is wrapped around a large hammer/sledge hammer handle, just below the head. With everything lined up right, you can swing the hammer which yanks the axle with more force than just pulling by hand. Give it a try, what's the worse that can happen - right?!

Did you still need help with your hubs? I helped my neighbor with his Sportsman last year, turned out the wire going to one of the hubs was snagged and broken, fixed it, refilled the hubs with oil and all good. I just checked each hub coil with an ohmmeter to make sure they were both good, and then drove it into a snowbank to make sure the front wheels broke traction. Yes, in case you don't know, when the hub coils are energized, the wheels still freewheel until you actually drive the machine under power, then the sprag clutches engage. Also, I think it's stupid the way Polaris makes you hold the "Reverse Override" button to get 4x4 in reverse, I mean if I want 4x4 I want 4x4, period. I get stuck in reverse more often than forward, especially with a plow. Yes, I spent some time looking over the (awful) wiring diagram. I'm sure you have your wiring diagram from the owner's manual (important)? If I recall correctly, you can simply apply 12v directly to the AWD switch, then you have true 4x4 on and off, period. No speedo, no override, just a nice simple ON and OFF switch (isn't that shocking these days? what no computer!!?.......:o) I still have the diagram can double check for you or send it if needed. Let me know if I can further assist. Bellarmine

Not sure I follow you, this is a two clutch system in 2004 but isn't it just a centrifugal clutch and a shifting clutch? Isn't the DCT system in a lot newer quads than this one?

haha.. I dunno but I had the same problem.. I went to make a post and it somehow got that vid in my post.. I cancelled the post becuase it kept doing it. The site has another problem the other day too. I reported to the Admin and he had it fixed in about an hour.. Contact the Admin.. I'd try using the manual shift lever and the buttons at the same time. If the shift motor is a bit weak your manual input will assist it to make the shift.. If the motor is trying to do the shift, you'll feel it assist your manual shift. If the motor isn't working at all, you will hopefully notice that. I think if you try a manual upshift, while pushing the down button, the two will fight oneother and you'll feel that.. I think.

Some models have a join in the earth wire hidden away inside the loom.. They can actually have several crimp earth connectors, and power connectors, hidden inside the loom. Oh, and some makes and models they do suggest resistance test and an output test.. It's not new. I always do an output test whether I have a figure for it or not..