Polaris 4x4 AWD magnetic coil removal on a Sportsman

[@buildurtruckurway9118]

I'm really hoping you might have the answer for me.
There's alot of different part numbers for these hub coils.
The newest part# claims to over lap a bunch but it costs over 200 to get it.
Will the coil from the trail boss or 400l work?
I don't mind soldering on new plug ends.
They look identical minus the plug so I assume they work but since I've seen both on your channel I figured I'd ask.

[@ussweeneyd]

More great instructions. Thanks.

[@stephenreschke407]

I'm wondering if you think my issue is the coil. Right wheel works, but left does not when switch is engaged. I changed armature plate as old one was bent. No dice. Armature plate magnetizes to the magnet especially when key switch on and awd switch on in gear as I understand its supposed to. That's why I'm not sure its a coil issue. Thanks

[@silkyjohnson3]

Awesome videos Man

[@michaelmcvay7054]

Thanks for sharing.

[@TitaniummanGarage]

Right On! Glad to help out.

[@osbornebay944]

Coil out easy, one of leads broken, coil is still reading good.

[@dons1493]

You don't need to heat ring to pull. NEVER use a hammer to remove ring, you will only to damage as you have shown us. Use a puller....1. Remove Hilliard assembly. 2. leave inner bearing in. 2. Put a pipe spacer between bearing and outer washer/nut to hold axle in place. 4. Use a puller to remove ring. VERY SIMPLE with no damage.

[@brandocalrissian9484]

What puller would you recommend for this application?

[@bobbygardner40]

You show how to remove the ring, so please show how to reinstall it. Thanks

[@mr.octopus6972]

I have a problem with the 4x4 on the left front wheel of my sportsman 1998.
I just changed every bearings, seals and clutch for a brand new kit.
Checked my job for a 1000th time to make sure it's ok. Everything looks and rolls just fine.
The AWD is just kinda WANTING to work but I can stop it from rolling with only 2 fingers. The clutch doesn't seem to do it's job properly.
I checked the resistance between the wires to the magnet, it says 23 omhs on each sides (my 2002 polaris has the same reading on both sides also).
The magnet when it's on can hold a small screwdriver but I don't know if it's strong enough ...
I'm totally out of ideas.
Anyone ?

[@TitaniummanGarage]

1) It could be a ground issue. Add a ground to the thick part of the 4x4 wires.
2) The outter ring on the magnetic coil could be bumped out of alinement. Take a strait edge and run it across both sides. use a flashlight to see if there are any gaps from the inner ring to outter ring. only the outer ring moves in and out. If not perfect. It won't magnetize correctly.

[@mr.octopus6972]

@@TitaniummanGarage i will check alignment. It seems like the outer rign is juuuuust a bit off...
What is that blue glue they use to make that hold ?
Will give you updates when done.

[@mr.octopus6972]

Update :
After checking everything again and again I decided to dismantle the other side to compare. I used the old clutch nut as a bushing so I could actually see the mecanism running without the hub installed.
Everything was the same on both sides but left clutch kept not working properly.
An idea passed trough my mind ( this was an Hail Mary attempt done by an helpless man one second away from unpluging the AWD permanently. Last resort inspired by God himself😅), i switched the clutches ...
IT WORKED !
Don't ask me why but it did.
What oil do you put in there ?
What is that blue "sillicon" that holds the magnet and it's wires ?

[@HFIWebSolutions]

Either you were smoking a cigar or its very cold there!

[@TitaniummanGarage]

David Hansen Very cold. 10 degrees out at the time.

[@jessiec7637]

My hub had a lip in front of the magnet destroyed old one getting it out and could not get new one in. Did your have a lip?

[@TitaniummanGarage]

I'm not sure what you mean by lip. There is the inner and outer ring. The outer ring around magnet has a lip to hold magnet in place. Inner and outer ring should be level with each other.

[@adrew1963]

good job di you check the coil with a meter and what value if any did you get and thanks for the good vid

[@TitaniummanGarage]

No, I just checked for voltage. Its a common problem, so when there's no voltage I just replace it. Thanks.

[@KR-Adventures]

How convenient I’m having water pump seal issues and possible magnetic coil issues hahaha so if one goes do you know if that will stop awd from working or making it 3 wheel?

[@TitaniummanGarage]

It would just stop the one wheel from turning. Lots of times both are shot.

[@KR-Adventures]

Titaniumman 2012 okay right on. I imagine that’s what’s going on mines a 07 800 but its the same thing basically. Had awd when I put it away in the fall didn’t when I started it. Sounds like a likely culprit.

[@TitaniummanGarage]

If it's an 07 I would check front differential fluid. Sometimes the front diff. Goes on those years.

[@beans8270]

Please tell me how to install it properly my dad doesn’t know anything about this

[@TitaniummanGarage]

Which part? Just the magnetic coil? Or the whole thing? Just slide the new coil on and slide the ring over it. Be careful not to damage the coil. Tap ring on till it is flush with inner ring. Take a strait edge and go criss cross to make sure all areas are flush with inner ring. Then install metal ring..make sure tabs line up with the clutch then the bearing,hub,other bearing and nut. Fill with at fluid through the little plug on the hub. And run wires up to power and ground. Hope that helps.

[@beans8270]

Titaniumman Garage you able to make a video explaining it? It would help alot. we want to go in the trails this summer and my dad hasn’t gotten to because hes not good at electrical stuff. He thinks by plugging in the new coil it would work 🤦‍♂️

[@beans8270]

Titaniumman Garage and he keeps thinking if the coil is not installed it should magnetize automatically

[@TitaniummanGarage]

@@beans8270 the coil IS the magnet. Electromagnetic! Once the switch is turned on power goes to coil/magnet grabs the metal plate with the tabs, turns hillard clutch and Boom! Front wheels turn.

[@TitaniummanGarage]

I thought I did. There is a part one and part 2. I don't have one with that problem right now. It's 50 bucks for a magnetic coil so taking one apart to shoot a video isn't cost affective.

[@tannerburk9528]

Werw did u buy the coils

[@TitaniummanGarage]

E Bay

[@timschannel910]

Did your 4x4 work after this

[@TitaniummanGarage]

Of course it did.

[@timschannel910]

I put mine into 4x4 but only one tire in the front moves when am on a hill the one on the left don't move at all. I noticed that on one side there is two wires going down to the one that's working but the other one only has one and that is the one that is not going into 4x4

[@TitaniummanGarage]

You'll probably need to rewire it if you can find both wires. Solder them together or spend the 45 bucks and get a magnetic coil. It works. You just have to make sure the outer and inner ring are perfectly level with each other.

[@osbornebay944]

@@TitaniummanGarage I have left reading 400 oms, right side reading " open", now reached the coil, ll use your way to take out coil.