Running out of ideas. Need suggestions please! 1997 Polaris Sportsman 500 HO (found out when purchasing the wrong axles). Blade is up front to move snow.
The Polaris rides like it has an oblong tire in the front. Checked everything from the outside wheel cover to the differential. Wheel bearings were good, only 3 tires rotated and the armature did not fix to the magnetic plate when 4 wheel drive was engaged. The axle to the CV joint was rotating, it appeared normally. Adjusted the bearing seal between the outer magnet and the inner coil housing to .0025, or at least had enough gap to have the magnet freeze the armature in place so all tires were turning when 4 wheel drive was engaged.
The Hillard Clutch's were good, strut bearings were good. Hubs were straight, replaced brake pads and loosened gap to allow less rotor drag. Bought new tires in case there was a belt malfunction but the nubs were all pretty uniform and the wheels prior to putting on new tires ran straight indicating the rims weren't bent, (another way to describe the ride is an oblong hop like a bent rim would ride). The hop is constant.
After fixing Hillard clutch, reassembled front drive leaving the wheels off and watched the hubs in 4WD. The front left was all over the place. I determined that since the axle was functioning properly and appeared straight to the CV joint, that all the irregularity had to be coming from the CV joint so I ordered new axles. Ended up getting axles for non HO Sportsman which were fatter and the strut bearings didn't fit but clutch and wheel bearings fit, may have been a little longer treads on the end which may not have sealed the front hub fluid very well. Anyway, took the L axle apart to see if the CV joint was malfunctioning but, took it apart, cleaned it and used CV grease to repack it, reassembled the axles as both the u joints and CV joints were fine, switched sides (L to R, R to L) on reassembly.
I moved snow with it hobbling all last winter, with no indication of wear on front drive train, (good bearings, clutch, hubs, rotors, brakes, proper 4WD Functioning), original axles were used in reassembly. Will be moving snow with the 500 riding with a malfunction somewhere. Hard to believe it hasn't appeared to be stressing the moving parts of the front drive.
Anyone have similar malfunction that could help me to look in the right direction?
Ritelobe
The Polaris rides like it has an oblong tire in the front. Checked everything from the outside wheel cover to the differential. Wheel bearings were good, only 3 tires rotated and the armature did not fix to the magnetic plate when 4 wheel drive was engaged. The axle to the CV joint was rotating, it appeared normally. Adjusted the bearing seal between the outer magnet and the inner coil housing to .0025, or at least had enough gap to have the magnet freeze the armature in place so all tires were turning when 4 wheel drive was engaged.
The Hillard Clutch's were good, strut bearings were good. Hubs were straight, replaced brake pads and loosened gap to allow less rotor drag. Bought new tires in case there was a belt malfunction but the nubs were all pretty uniform and the wheels prior to putting on new tires ran straight indicating the rims weren't bent, (another way to describe the ride is an oblong hop like a bent rim would ride). The hop is constant.
After fixing Hillard clutch, reassembled front drive leaving the wheels off and watched the hubs in 4WD. The front left was all over the place. I determined that since the axle was functioning properly and appeared straight to the CV joint, that all the irregularity had to be coming from the CV joint so I ordered new axles. Ended up getting axles for non HO Sportsman which were fatter and the strut bearings didn't fit but clutch and wheel bearings fit, may have been a little longer treads on the end which may not have sealed the front hub fluid very well. Anyway, took the L axle apart to see if the CV joint was malfunctioning but, took it apart, cleaned it and used CV grease to repack it, reassembled the axles as both the u joints and CV joints were fine, switched sides (L to R, R to L) on reassembly.
I moved snow with it hobbling all last winter, with no indication of wear on front drive train, (good bearings, clutch, hubs, rotors, brakes, proper 4WD Functioning), original axles were used in reassembly. Will be moving snow with the 500 riding with a malfunction somewhere. Hard to believe it hasn't appeared to be stressing the moving parts of the front drive.
Anyone have similar malfunction that could help me to look in the right direction?
Ritelobe
