2003 Polaris Sportsman 400 - Right front tire will not disengage from AWD

[wjmedic]

Recently rebuilt front end on this Polaris 400. New axles, bearings, seals, control arm bushings, Hilliard clutch thoroughly cleaned and inspected with no damage noted. 

Everything put back to together. Placed bike on jack stands all four wheels off the ground, started in 2 WD switched to AWD both front tires spinning, when AWD turned

off right front wheel will not disengage from AWD. Checked voltage at connectors both left and right connectors have no voltage with AWD switch off, and both have 12.4V

when AWD switch is turned on. Repeated turning switch on and off several times with no change in condition. I am thinking this must be something mechanical with the 

Hilliard clutch on the right hub ie. weak spring or stuck rollers on the Hilliard clutch assembly (Is this a logical thought?) any ideas on trouble shooting this before I disassemble the 

right front hub again 

[Gwbarm]

Good diagnosis! It could be either but im guessing stuck or binding rollers on the clutch assembly not letting it release completely.

[wjmedic]

The only other thing I think of is maybe I did not get the armature plate back in the same position 

as what I removed it. But I am pretty sure the little tabs on the armature plate were seated well in 

the grooves on the Hilliard clutch when I put it together. Thank you for responding!!!!!!

[Mech]

Try driving it. You can't test the awd on a jack, it needs the back wheels to be turning faster than the front wheels to make the clutch engage. It might be that it needs the opposite process to disengage When it's on a jack, and the first wheel disengages, then there might not be enough torque/rotation between the second wheel's wheel and axle to disengage it.