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Discussion Starter · #1 ·
my 08' rzr standard 800 is having issue, the front wheels will only pull in 4wd when in reverse! they will not pull when in high or low range(forward gears) with the switch on the 4wd light does light on the screen and stays lit, but front wheels will not pull in forward gears only reverse!

common issue?

would like to fix myself gettin ready to add superatv +5 "s" conversion long arm kit would be good time to pull front diff. and fix...

is this possibly the common sprague carrier fail? i plan to upgrade to the billitt superatv sprague if so...

thanks,
kevin
 

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Could be the sprag cage but would not likely work in reverse either if it is trashed. I would pull the gear indicator switch off the driver's side of the gear box and clean the connections well...that may be your problem and a simple solution to try before you open up the Demand Drive unit.
 

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Discussion Starter · #3 ·
Could be the sprag cage but would not likely work in reverse either if it is trashed. I would pull the gear indicator switch off the driver's side of the gear box and clean the connections well...that may be your problem and a simple solution to try before you open up the Demand Drive unit.
i will try that, no one would have pics or link to discussion on this gear indicator switch and its exact location?
 

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I don't think its going to be the indicator on the side of the trans, unless it is not showing that it is in "H" or "L".

Mine is doing the exact same thing, only has 4wd in reverse. The "H" and "L" along with the "4wd" indicator, all show, but there is no 4wd in the forward gears.

A couple of 1000 miles ago, I had my gear position switch indicator go bad....it would not always show that it was in "H" or "L", and when it did not show the gear position, the 4wd would not work. I changed out the switch and the 4wd worked.... until now.

I believe this problem of only having 4wd in reverse is a different issue.

I have 6400 miles on my 2008 and it has the original plastic sprague. I am going to pull my front diff and check it out.
 

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i had the same problem on my 08rzr. there is a plug under the drivers seat that doesnt plug into anything. it has some kind of circuit board in the end of the plug that was full of dirt and not making contact. i clean it realy good and put dielectric grease in it. 4x4 has worked great ever since. hope this helps
 

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I just fixed my 4wd problem a few minutes ago, it had 4wd in forward gears but no reverse, but I noticed the display stopped showing the "R" on the dash so i cleaned the nasty relay under the seat didn't fix it, I pulled the selector switch and used my multi meter and checked for resistance from plug to selector housing and found one pin not showing resistance. I then drilled out the epoxy filler to uncover the wire going to the pin on the switch and added a little solder to the connection. It works perfect now, but this only fixes the problem with no 4wd when a gear doesn't show up on the speedo. Hope this is of some help to you or any looking.
 

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Discussion Starter · #7 ·
all very goo and helpful tips which i am going to try... does anyone know the symptons of bad sprague? mine is still original plastic sprague and i have feeling it could be problem but i would like to kno the symptoms
 

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If you put it up on jack stands (front and rear) and put it in gear with the AWD "ON" you should be able to hear a bit of rattling/nasty sounds from the drive unit. Try going from forward gears to reverse gears a few times and listen (ALWAYS let the RPMs drop and aply the brake before shifting, of course). You will most likely hear components of the cage/spring/roller assembly moving around if the cage is fragmented but possibly not. If you have the plastic assembly I would not worry about that test and just order a billet cage and replace it even if it is intact. JMO, YMMV.
 

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Discussion Starter · #9 ·
If you put it up on jack stands (front and rear) and put it in gear with the AWD "ON" you should be able to hear a bit of rattling/nasty sounds from the drive unit. Try going from forward gears to reverse gears a few times and listen (ALWAYS let the RPMs drop and aply the brake before shifting, of course). You will most likely hear components of the cage/spring/roller assembly moving around if the cage is fragmented but possibly not. If you have the plastic assembly I would not worry about that test and just order a billet cage and replace it even if it is intact. JMO, YMMV.
thankyou i will do the test but yes i have plastic one still, ordering super atv +5 "s" suspension will get billet sprague carrier from em and install same time...
 

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Discussion Starter · #10 ·
i had the same problem on my 08rzr. there is a plug under the drivers seat that doesnt plug into anything. it has some kind of circuit board in the end of the plug that was full of dirt and not making contact. i clean it realy good and put dielectric grease in it. 4x4 has worked great ever since. hope this helps
found this tonite mine was completely caked in mud! before removing it to clean my gear selector on screen would RARELY show "P" for when in park it would jus be blank in park though other gears would always show on screen... after cleaning it it would show "p" for park havent had time yet to test 4wd though hope this fixed it... didnt have any dielectric grease on hand going to put some on it tomorro though before actually riding it... would like to seal it better move it to higher location than ziptied to that big wireloom along framerail against skid plate like that of course its taking on mud that low
 

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UPDATE: THIS IS WHAT FIXED MY ISSUE.
As I stated earlier in my post to this thread, mine was doing the same thing, 4wd in reverse only. My gear indicate was working as well as the 4wd indicator, but no 4wd in either "H" or "L".

Mine still had the original plastic sprague....I have over 6000 miles on the RZR. My plastic sprague was shattered....I am surprised it still worked in reverse. Numerous plastic pieces, the armature and "H" clips look good, actually the whole diff with the exception of the plastic sprague looked like new yet.

I replaced the broken plastic sprague with a new aluminum one from "Super ATV".

Working as it should now, ready for the trails.
 

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I need help Bad!! I couldn't do anything with the bike the weekend. I order a gear indicator switch and a new pack. (still waiting on them & hope I order the right thing) I'm trying to get what gear I'm in, the speed & AWD wheel drive to show up on my dash. I can hold the mode button and the 4x4 works. Also everything else on the dash works fine (gas/clock/rpm/etc. So It leads me believe it's and electric problem. Because everything worked PERFECTLY before I reinstalled a new alba racing motor in it and now this cramp. I no there is nothing wrong with the front diff. due to the fact I could easy right up a tree before reinstalling the new motor. Do any of yall have any suggestions for me! Any information would be greatly appreciated!!! The bike runs like a dream now other than no AWD :(, spend limit, and showing what gear I'm in. You can pm me or send me a text and walk me thru It I just wanna fix it asap because summer is coming up and these is something that me and my daughter bond during ride now and it want to do as much possible with her before she hit that teenage stage. THANK YOU 2517144470
 
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