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!!!!!!

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

After riding for 20 minutes or so check engine hot flashes, I then stop and idle, fan will kick on run briefly warning goes out. oil, coolant, are both full. The fan appears to be working but does not always come on when I stop and just let it idle while the warning is flashing. Can turn engine off with warning flashing, fan does not run, can immediately restart warning resets does not flash fan does not run, runs fine, a short time later warning will come back on. Trying to decide if this is a flow problem maybe thermostat or sensor problem. Have repair manual on order has not arrived yet.

New to the forum, just glancing around wow what a wealth of experience and knowledge that is gathered here. Look forward to reading more.

Hi there new to the site, just purchased a 2006 Polaris Sportsman 450/ Browning Edition has 139 hours looking for free repair manual for the starter, frequently when starting the starter grinds and does not appear to be engaging the flywheel, however most of the time on second try it starts with no problem. To me grinding is bad sign of worse things to come or is it a common trait with the 450"s. Thank you for any thoughts you can provide.