Polaris SPORTSMAN 600 Service Manual page 186

FINAL DRIVE
8. Install the shim onto the ring gear.
9. Install the armature plate onto the ring gear.
NOTE: Be sure armature plate tabs are placed into
the slots on roll cage.
10. Apply grease to the thrust bearing. Insert the
thrust bearing onto the output hub. Insert the
output hub, dowel, and thrust bearing into the ring
gear.
7.14
11. Install output cover with new o-ring and torque
bolts to 14 ft. lbs. (19 Nm).
Cover Bolts Torque
14 ft. lbs. (19 Nm)
12. Install new seals into the gearcase housing and
gearcase housing cover.
EARLY 2004 - - FRONT
GEARCASE DIAGNOSIS
Symptom: AWD Will Not Engage.
1. Check the gearcase coil resistance. To test the
gearcase coil resistance, use the coil harness
(Grey & Brown/White). The gearcase coils should
measure between 22.8 ohms and 25.2 ohms.
2. Check the minimum battery voltage at the wire
(Grey & Brown/White) that feeds the hub coil wire.
There should be a minimum of 11.80- -12.0 Volts