Need to know how a 95 polairs xplorer 400 4wheel drive work just changed the front left cv and it wont lock in?

Answer 1

these can be a bit of a pain without a service manual. Make sure the two wires (grey and brown wires) coming out of the hub have a resistance of 25 - 30 ohms at the circuit board(behind the rad/oil resevoire cover). Make sure you didn't break any wires at the hub. they are very small. If resistance is good than check to make sure you put everything in the hub back in properly. Make sure tabs on the armiture plate(washer with tabs sticking out) are properly engaged in the hilliard clutch. If you know you got all that right you should check the clearance between the outer and inner poles. You will have to pull the entire hub assembly of again to do this. once the hub is off you should see the inner and outer poles. Put a very straight edge across the two and shine a light in the back. I like to use a trowel or a new putty knife. It is still thin enough that you can see what you are doing. You should not see any light or very little. With a feeler guage check the gap. Factory spec is 0.00-0.001 inches. I usually just put them at zero. seems to work better. when that is set turn the key on and the 4x4 on. put a bolt across the two poles. it should be magnetic. just more than enough to grab the armiture plate. the further apart the poles are the less magnetism it will have. If the poles are set to far the other way(inner sticking out past the outer) the hub may not release or engage at random. usually at wide open throttle and 40mph. you will know because it will pull you uncontrollably to one side.

If none of the front wheels are engaging than make sure the switch in the gear selector did not get destroyed. I had that on mine. Easy to bypass though.

good luck