Troubleshooting, Front Gearcase (Adc) - Polaris Sportsman 850 Service Manual

FINAL DRIVE
TROUBLESHOOTING, FRONT GEARCASE
(ADC)
Customer Complaint: ADC not functioning
Verification of complaint: Drive vehicle with ADC switched on and off down a grade if possible to determine if ADC
(Auto-lock is working correctly). May need to be in low range to tell in high traction areas. Make sure switch on handle
bar is on ADC mode. Make sure ADC light is lit on gage pod. Vehicle must be in hi, low, or reverse. Also, vehicle
throttle lever must be off. If complaint is warranted, move onto component check list. If no, move onto other vehicle
components (suspension, driveline, engine, etc.) Vehicle may also be tested in air. All 4 wheels need to be off ground,
put into ADC mode and roll back wheels if possible. Rotate cover side front wheel forward and back, should feel roll
cage in front drive index and lock the front wheel to the drive line. This can only be done on the cover side wheel. It is
also best to make sure 4x4 is not engaged any more. This way is possible to test but best way is to ride vehicle down
steep hill as stated above.
POTENTIAL
PROBLEM
Unplugged / damaged
wire connector.
No power from vehicle to
front differential (blown
fuse)
ADC Coil Short
4x4 Not turning off
7.46
DIAGNOSIS PROBLEM
PROCEDURE DIAGNOSIS
Check to see if ADC light No ADC light on gage
is lit on gage pod. pod.
Check wires to see if there Cut wire.
are any visible cuts or
nicks.
Check to see if front Unplugged
differential is plugged into
wire harness.
Unhook wire connector to No power to front
front differential. Using differential wire harness.
multimeter determine if
vehicle wire connector is
getting power to the front
drive on two outer most
pins.
Check resistance of coil Coil to be +/- 4 ohms to
nominal
Check continuity to both Continuity should be
leads present between leads.
Check continuity to case No continuity between
Check continuity to case either lead and the case.
Lift Vehicle off ground. Power to 4x4 is not
turning off when ADC is
Rotate cover side wheel in
both the forward and turning on.
reverse direction. If it locks
to the drive train in only
one direction, ADC is not
indexing cage in both
directions
REPAIR REPAIR
PROCEDURE VERIFICATION
Problem might not be front N/A
differential related. Check
electrical system in
vehicle.
Replace output cover (Unit Drive vehicle with ADC
will need to be removed mode on to determine if
from vehicle to do repair.) problem has been fixed. If
not, continue onto
additional problems listed.
Plug wire harness into Drive vehicle with ADC
front drive connector. mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
Problem might not be front N/A
differential related. Check
electrical system in
vehicle.
Replace output cover (Unit Drive vehicle with ADC
will need to be removed mode on to determine if
from vehicle to do repair.) problem has been fixed. If
not, continue onto
additional problems listed.
Replace output cover (Unit Drive vehicle with ADC
will need to be removed mode on to determine if
from vehicle to do repair.) problem has been fixed. If
not, continue onto
additional problems listed.
Replace output cover (Unit Drive vehicle with ADC
will need to be removed mode on to determine if
from vehicle to do repair.) problem has been fixed. If
not, continue onto
additional problems listed.
Problem might not be front N/A
differential related. Check
electrical system in
vehicle.