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Jeff011366

2002 Polaris Sportsman 700 front and rear diff questions

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Hello,

  Over the years I have always used a friends machine, and only ride a few times a year. Last week I purchased a 2002 Polaris Sportsman 700. The front diff needs a rebuild, the axles are very loose where they go into diff. My question is, both front wheels rotate forward by hand, but do not rotate the opposite direction. Is this "NORMAL OPERATION" I plan on rebuilding the hubs at the same time as the diff.....

 

  My question about the rear diff, it rolls as if the machine has a total POSI rear axle...……. I lifted the front end off the garage floor with overhead hoist, as I moved it sideways the rear tires skidded rather than rotate. Both would roll forward easy, but not go in a circle. When I drove the machine in the garage making a tight turn I could feel the binding and skidding of rear tires....  Even if the switch was in 4 wheel drive, when it's hanging in te air the ignition is off...….. with the machine in 2 wheel drive mode, is that HONESTLY 1 wheel drive to allow turning without tearing up the lawn? then it locks the rear axle once it's put into 4 wheel drive? I'm guessing the rear diff needs a rebuild also because there is something "BALLED UP" internally locking the rear wheels together?

  It's a old machine that was not maintained, I thought the wheels were all rusted, but it was 17 years off baked on red clay. Just wanting to make it a reliable machine. I have great mechanical ability, just lacking a little knowledge of what is suppose to be "NORMAL OPERATING STANDARDS"

 

Thank you in advance for sharing your knowledge.

Jeff

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Sounds like the front diff needs help alright but the rear is normal - both axles are "locked up" together at all times. It really isn't a differential on the rear, usually called a gearcase btw.

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  • Thank you for sharing your knowledge with me, I did a little research today and learned the inner workings of the rear gearcase. I wasn't sure if I would clean this machine up and resell it, or invest time and money into making it a nice riding, reliable machine. I priced out the parts for the front gearcase, along with a couple U-joints, and bushings. for a few hundred dollars it should be a decent machine to keep around.

        Let me ask, when I rebuild the front gearcase would it be smart to invest in the output hubs the axles slide into? Do the spines wear out, or do you think it only needs the bearing, seals, and Sprague? I just want to make sure once I open it up I have all parts needed to put it back together. But at the same time I don't want to waste money on parts it doesn't "NEED"...….the machine has 4400 miles.

 

   Again, Thank you for your input......

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If they're not leaking, just keep running them! The hubs run a small amount of ATF in them for lube.

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The prop shaft needed joints at both ends, and this machine is just abused to death...…..I don't believe it was EVER washed, so was it ever greased? I have the front gearbox apart on the bench currently. The bearings are a little loose...….and making noise. I built race cars and engines for 35 years.....so I understand what bearings should feel and sound like....these were READY. I will also put in a new set of axles to help take out some slack in the driveline.

  I took some of the back of the machine apart to access some things. The left rear hub is FLOPPING loose, and the rear prop shaft seems to float in the splines on BOTH ends...….. I'm sure it needs to float on one end.....but not sure about both ends floating. Big wobble to get prop shaft to center up and rotate on a axis...…. the previous owner just put in both rear joints, but no yokes. I'm thinking when I pull the rear gearbox out it's getting new yokes, along with all hub bearings...…

 

before I pull the back apart I need to put the front back together...…...or I might have to come on here to ask LOTS of questions. I have a coffee can of bolts now...…….every time the can gets full that means it's time to put something back together for me, or I will get too overwhelmed..

 

Thank you for the input, it's much appreciated.

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I've noticed allot of play in my axles too. But I do believe there is supposed to be some to keep down binding. 

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