Locked2007 800 sportsman front diff wont engage??

Post
Goat_Rope
Grass Hog
2011/01/11 07:23:37
the screen lights up saying its in 4x4 but the front diff. isnt kicking in.  I know its not the switch because its reading to the screen.  It just wont kick in.  Do you think it could me my accuator?
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 07:45:47
theres not a actuator  first if you haven't change the fluid and make sure you use the polaris demand drive fluid.  also check the wire going into the front diff to make sure there are no breaks in the line.  you may have a broke cage which is what engages in the front diff for the 4 wheel drive. 
Goat_Rope
Grass Hog
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 08:17:04
so would I have to replace the front diff if the cage which engages it is broken?
 
lost cause
Mud Pro
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 08:49:15
if it is just the cage then you can replace just the cage.
Goat_Rope
Grass Hog
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 08:58:25
is it expensive and/or hard to change?  should I get me a test light to see if Im getting power to the differential end of the plug?
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 09:14:15
I sent you a pm back goat
Goat_Rope
Grass Hog
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 13:48:04
Hey, Thanks alot man.  I used the brute force differential fluid for the polaris when I changed its fluids.  Will it make that much of a difference?  Also, how do I know if its the sprague cage?  How do I know that the sprague cage is broken?  Will something be worn down, broken, ect.???
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 14:26:19
change the fluid that is most likely the problem since you put regular oil in the front diff that is what goes in the brutes diff.  It needs the polaris demand oil because there are roller pins in the cage that have to slide back and forth to engage the 4 wheel drive if the fluid is to thick they will not be able to engage. the front diff on the polaris is very very picky on the type of fluid thats in it.    From the sound of your problem its not going to be the cage usually you'll hear a crunch or the 4 wheel drive will be going in and out of 4 wheel to 2 wheel and locking up.  this is what you need

post edited by TexasMudderBF650 - 2011/01/11 14:28:51
Goat_Rope
Grass Hog
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 15:10:10
Do you think it may be the clutches in the diff.  Someone from the polaris dealer said to make sure that the drive shaft isnt stripped which I dont think it is considering it has a pin that goes through it.  Ill change that fluid and see what I get.  He was saying that if its getting power to the tip of the plug by the diff., and none of the axles or drive shaft is broken then its the differential itself.  Thats not true huh? 
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 16:13:05
sounds like you need a new dealer : ).  get all of the oil you put in there out of there and put in the proper demand drive and drive it around a bit then see what you get.  And on a side note the best way to test to see if the 4 wheel drive is working is to jack up the bike with all 4 wheels off the ground and put in gear and awd and give it alittle gas.  all 4 tires should spin then.  
Po_700_Po
Mud Master
Re:2007 800 sportsman front diff wont engage?? 2011/01/11 20:35:51
TXmudderBF650 is correct here. The fluid is likely the culprit.
rusty2198
Mud Bogger
Re:2007 800 sportsman front diff wont engage?? 2011/06/06 14:58:11
I have the same problem I think its the cage
bobcat
Mud Monster
Re:2007 800 sportsman front diff wont engage?? 2011/06/06 16:08:40
What about if it just doesn't work in reverse but the light is working and moving forward it works?? 
Re:2007 800 sportsman front diff wont engage?? 2011/06/06 16:13:52
bobcat

What about if it just doesn't work in reverse but the light is working and moving forward it works?? 

are you holding in the yellow button on the left handle bar while in reverse it has to be held for 4x4 to work in reverse.
bobcat
Mud Monster
Re:2007 800 sportsman front diff wont engage?? 2011/06/06 16:18:33
Yeah, I just noticed it wasn't engaging about two rides ago.
I pulled it into my shop the other night and jacked it up and it will work in forward but reverse, it won't engage. I know the button is working because it's overriding the rev limiter
lost cause
Mud Pro
Re:2007 800 sportsman front diff wont engage?? 2011/06/07 09:33:24
When i broke the cage in my diff., i started noticing that it would not engage in reverse, then finally just quit engaging all together. First thing to do is to change the fluid and check your wires to the diff. If that doesn't work then it is most likeley the cage witch is really easy to change. I did mine in about two hours total. That includes taking off front tires, axles, and unbolting the diff. Make sure you get all the little broken plastic pieces from the cage out of there. Another thing you might check also is the input shaft. Not that anything is broken, but I took mine apart and there was some sand inside it so I just went ahead and thouroughly cleaned the diff while I had it out and apart.
bobcat
Mud Monster
Re:2007 800 sportsman front diff wont engage?? 2011/06/07 16:43:58
Cool Thanks for the help