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post #1 of 5 Old June 8th, 2017, 07:16 PM Thread Starter
 
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Front Diff Engagement - Head Scratcher

I have done all the testing and rebuilding that I can think of minus a new diff half with coil. Im not sure that's even the problem but was hoping someone could chime in to help me. I have been researching this over the last week and nobody seems to have had a similar problem that I can find. This is on a 2008 800EFI RZR

I have tested the resistancce and it checks out OK at 23 ohms
I have replaced the sprague, rollers, and springs with a Niche setup
I have tried a new armature plate
-The old one is straight but had grooves
-The old one sticks to the magnet much better than the new one does
-I can't turn the old armature by hand when engergized
I cut the plug off the diff to eliminate the possibility of a bad plug - same results
Magnet ridges are even as I checked with a straight edge

When i run 12v directly to the diff from a battery it turns with more resistance but doesn't engage the outer hubs.

Is there anything else i can test before ponying up for a new differential side plate and magnet?

Thank you so much!
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post #2 of 5 Old June 9th, 2017, 08:22 AM
 
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Re: Front Diff Engagement - Head Scratcher

I know dumb question to follow.

Do you have the correct fluid at the correct level in the front diff? The front diff is very sensitive to dirty fluid, too high or too low fluid level and correct fluid. I'm sure the fluid is clean, you probably changed at least a couple of times during troubleshooting. The front diff needs 6.75oz of the correct fluid. polaris calls it "Demand Drive" fluid

Mike
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post #3 of 5 Old June 9th, 2017, 10:31 AM Thread Starter
 
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Yes I am using the correct fluid. I fill it on the bench (pretty level) until it runs out the full hole as described in the service manual.

Just picked up another armature pltefrom the dealer ($$$) and it seemed perfectly flat on their plate glass door so we'll see if that makes a difference. I'll keep this post updated.
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post #4 of 5 Old June 13th, 2017, 11:05 PM
 
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Re: Front Diff Engagement - Head Scratcher

Any update


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post #5 of 5 Old June 14th, 2017, 05:02 AM Thread Starter
 
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Yes, sorry I was so happy it worked that I forgot to update. It seems like the perfectly flat armature plate fixed it. The aftermarket ones I got were nearly flat but even 1/32" of warp made a huge difference in my machine. On the bench it seemed a little hard to disengage but it seems to be working correctly in the machine.
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