Polaris SPORTSMAN 600 Service Manual page 195

NOTE: Be sure the square O--ring is placed flat on the
cover surface, if the O--ring is twisted fluid leakage
may occur.
Cover Bolts Torque
14 ft. lbs. (19 Nm)
13. Install new seals into the gearcase housing and
gearcase housing cover.
LATE 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
present for proper operation.
3. Inspect the armature plate for a consistent wear
pattern. There should one or two distinct wear
bands (one band inside the other). If only one
band of wear is present (or if there is wear
between the two bands, inspect the coil area as
indicated in Step 4. A band with an interrupted
wear mark may indicate a warped plate, which
may cause intermittent operation. See Illustration
1.
Armature Plate
Check for wear bands
FINAL DRIVE
7.23