Awd Diagnosis - Polaris Ranger 500 2x4 2007 Service Manual

AWD Diagnosis

Symptom: AWD Will Not Engage.
1. Check the gearcase coil resistance. To test the gearcase
coil resistance. Test between the Grey & Brown / White
wires. The gearcase coils should measure between 22.8
ohms and 25.2 ohms.
Front Gearcase Coil Resistance:
22.8--25.2 Ohms
2. Check the minimum battery voltage at the Gray & Brown
/ White wires that feed the hub coil voltage. There should
be a minimum of 11.0-12.0 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 the following illustrations.
Armature Plate
Armature plate design may
differ from what is shown
Check for wear bands
Bad Condition
(Wear from coil
on armature plate)
4. Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase cover. The top of the coil
should be seated below the U-shaped insert. The U-shaped
insert controls the pole gap. If the top of the coil is above
the surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system. If this is the cause order a new Plate Cover
Assembly.
Gearcase Cover
Side cutaway view of
Centralized Hilliard cover
FINAL DRIVE
Possible
Wear Ring on
Armature Plate
OK Condition
Coil
U-shaped insert
7.17
7