I have two RZR 2007. On Both units the front 4x4 started going out intermitinly then went out completely after only 120 miles. The dealer said he fixed the first one under warrenty and it went out again after five miles the other one is still at the dealer to be fixed.. Anyone else had this problem. I run these in sand only other than the 1/4 mile trip from the staging area to the dunes. I had the 4x4 button on all the time. any help woud be great.

We have had several clients break theirs as well. The parts have been on back order for over a month. We broke ours and it was fixed and we have put another 250 miles on it and it is still running strong.

__________________
Thanks,
Kelly
www.hotride4u.com
sales@hotride4u.com

Im having a front end problem with mine lately too. Sometimes it works and sometimes it just doesnt. Just this last weekend I got stuck on a hill because the front end just wouldnt kick in. Any idea what it was that your dealer fixed on your rzr?

He said the plate was warped .It has happened twice now on both my units.I talked to the tech today and he said he could make some kind of shim and it would be in 4x4 full time which is fine with me as we are only in the sand. There is also a weak link in the trans .There is a pin that works out .I was lucky it fell to the drain plug and we found it with a magnet but had to pull the motor and trans to fix it, the factory warrenty did fix it,they sent the same pin to install and when I saw it was not tapered or a press fit I had it tack welded so that will not happen again. The polaris tech line was no help at all they said OH ! we have never heard of that ,but everone up here is having the same problems.
Thanks for the help.

My rzr is still under the 6 month warranty so they can fix it and I will find out what was wrong. When its engaged it rips up hills. I primarily have been riding mine @ dumont and you can definitely tell when the thing isnt working. You would think they would have a fix for the problem? Just replacing the front end with the same parts that dont work too well doesnt make too much sense.

most likely it will be your roller cage in the front diff.
i have been through 2 of them already

I was just told at the dealer when I picked mine up that it is a big no-no to jump with the awd button on. Anyone else hear this, I wonder if this could be part of the problem?

its no problem if your not on the gas when you hit.

What kind of failure? Is the cage cracking, the rollers wearing, the H springs breaking? The Hilliard is a simple mechanism but for it work correctly everything in it has to be in spec.

__________________
_______________________________

Now a 2-Rzr household.
Romeo, MI
http://tinyurl.com/8ltm8
______________________________

on my first cage, it just cracked a piece off, told my dealer i had a ride
coming up and the cage was on back order, so he took a diff. out of a brand new rzr and put it in mine under warrenty, went to the ride and made it 23 miles and AWD was out again, i took the diff out this time and brought it to the dealer and we opened it up and the cage was broke in two. i had 1300 miles before the first diff went but that was pretty much all summer and fall riding, i did some winter riding before the first diff went but not overly much. i am starting to think that the plastic roller cage does not like the cold very much, and not to drive it in awd on ice, so i am waiting for the diff to be repaired and have ordered another rollercage so i can rebuild it myself at home

My AWD isnt working right and when I took it to the dealer they told me they probably couldnt help me! They said Polaris wouldnt do anything for them. I ride primarily out at Dumont and the AWD seems to work fine for a while and then after about 15-20 minutes I will notice the front wheels arent pulling. To confirm it I go up to the base of a dune and try to go up from a dead stop. The front wheels just sat there as I got stuck. Their genius way of testing the AWD at the dealer is putting a jack under the back and flipping the AWD switch. If it pulls it works. I dont know what to do from here and havent gotten through to Polaris if they will even do anything for me. I have a feeling this is a problem most wouldnt even realize unless your out in the dunes where you know when your AWD isnt working when your going up a dune. There isnt any weird noises and the AWD indicator stays on.

Might want to find a dealer that is willing to put a little more effort into your issue, especially if your machine is still under warranty. Sometimes the warranty seems to be only as good as the dealer your working with.

My AWD was working part time also. I run a track kit on RZR in the winter. I took the front diff out myself. The thrust washer for the backlash ajustment was all rolled up and rolling around in the diff. Polaris replaced it with a new diff. Sounds like they are having a little problem.

Good news. My dealer finally put some effort in. Last Friday they notified me that to further investigate they would be working with a Polaris tech and dissembling the front diff. We will see what they tell me the problem was. Trying to get it fixed...warranty is up the 11th of April!

These machines are starting to worrie me. Snaped my front end two days ago just crawling around the camp site, my rzr is a month old. I'm thinking about getting rid of it but my girlfriend wont let me, whats the point if you have to drive them like a golf cart to not break them? She'll be driving it from now on, I'll stick with my 06 trx450er, 2 years old havent touched the motor since the hot cams stage 2 was put in and still with out run a 525 outlaw. $17 000 seems to be a lot for something that is about as useful as a golf cart right now.