Anyone familiar with hilliard clutch operation? Polaris 4wd?

[rusty ol ranger]

Yes i know it should be in the non RBV tech section, but id like as many as possible to see this....

01 sportsman 500 h.o 4wd.

Ive been trying to get my 4wd working now for a year. Ive changed so many parts, spent so many hours, and so much coin im bout to lose it.

But my question is, when you pull the hub/rotor combo off the quad, lay it upside down, and fit the hillard clutch into place there is a huge amount of slop in it (1/8-1/4in). Im wondering if the hubs themselves are wore to the point that the expanding rollers cannot grab the hub anymore to engage 4wd. Everything else seems to be operational.

The hubs are no longer available new, so id have to buy used, but according to what little info i could find the hubs dont usually wear out. But its all thats left, unless im misfireing here and not seeing the whole picture.

This sounds foreign to anyone not familar with this, but im hopeing someone is. The polaris forums dont wanna help anyone who isnt asking about performance or jumping stuff.

 

[85_Ranger4x4]

Tried YouTube? Lots of tutorials for my Honda 3eheelers on there

 

[Snoranger]

I haven't looked at one of those in years. I'm assuming that if you're asking about air gap, your magnets working, the lock ring tabs are good, the splines aren't stripped, etc? I want to say 1/8"+ is normal, but I can't recall the spec for sure.

 

[rusty ol ranger]

Tried YouTube? Lots of tutorials for my Honda 3eheelers on there

Yes, nothing that answers my question though

2 AMsnorangerI haven't looked at one of those in years. I'm assuming that if you're asking about air gap, your magnets working, the lock ring tabs are good, the splines aren't stripped, etc? I want to say 1/8"+ is normal, but I can't recall the spec for sure.

Good magnet at the coils. Plates/clutches/bearings are new. I have run the machine with the hub removed and can watch the hilliard rollers expand. So thats why im thinking the hubs are shot. I found a bunch of metal shavings to with no obvious source. The inner hub has a slight groove to it, havent yanked the other side yet.

But after expanding the clutch by hand it doesnt seem like it would even hit the hub. I tried to measure the inner hub but my micromrter didnt have long enough slides.

Also its all torqued by the book and filled with proper fluid and level.

 

[bfunk]

Yes i know it should be in the non RBV tech section, but id like as many as possible to see this....

01 sportsman 500 h.o 4wd.

Ive been trying to get my 4wd working now for a year. Ive changed so many parts, spent so many hours, and so much coin im bout to lose it.

But my question is, when you pull the hub/rotor combo off the quad, lay it upside down, and fit the hillard clutch into place there is a huge amount of slop in it (1/8-1/4in). Im wondering if the hubs themselves are wore to the point that the expanding rollers cannot grab the hub anymore to engage 4wd. Everything else seems to be operational.

The hubs are no longer available new, so id have to buy used, but according to what little info i could find the hubs dont usually wear out. But its all thats left, unless im misfireing here and not seeing the whole picture.

This sounds foreign to anyone not familar with this, but im hopeing someone is. The polaris forums dont wanna help anyone who isnt asking about performance or jumping stuff.

 

[bfunk]

Rusty ol Ranger did you ever find your problem with your hilliard clutches or hubs. I'm looking into the same thing. When my clutches are expanded they are still. 090" smaller than the hubs that I measured with a snap gauge and mic. I ordered used ones and they are the same. I don't know if it's the hubs or the new clutches. Thanks

 

[rusty ol ranger]

Rusty ol Ranger did you ever find your problem with your hilliard clutches or hubs. I'm looking into the same thing. When my clutches are expanded they are still. 090" smaller than the hubs that I measured with a snap gauge and mic. I ordered used ones and they are the same. I don't know if it's the hubs or the new clutches. Thanks

Just pm'ed ya back.

But heres a copy paste

I did figure it out.

I replaced the hillards with some cheap caltric ones. The cages were so flimsy that when id torque them down they would deform and basically make the rollers "stick" inside them.

The rollers would come out but there was some resistance there. I filed them down untill the rollers basically would fall out. The 4wd then worked properly

I ended up buying some used OEM clutches on Ebay for like 30 or 40 a piece. The 4wd works very well now. Its still a bit goofy in reverse (it engages a little slow and the one side sticks unless i hammer it in reverse in 2wd) but other then that it works great.