Awd Diagnosis; Front Gearcase Removal - Polaris RANGER XP 900 2013 Manual

FINAL DRIVE

AWD DIAGNOSIS

Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the coil
resistance, measure between Grey and Brown/White
wires. Measurement should be within specification.
Front Gearcase Coil Resistance: 21.6 - 26.4 Ohms
2. Turn the ignition and AWD switches on and place
gear selector in High or Low gear. Check for
minimum battery voltage at the Gray and Brown/
White chassis wires that power the coil. A minimum
of 11 Vdc should be present.
3. If electrical tests are within specification, remove
gearcase (see "Gearcase Removal") and inspect
components.
4. Inspect armature plate for a consistent wear pattern.
There should be 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 5. A wear band with
an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
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9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual
5. 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 found, replace the
cover plate assembly.
6. Inspect the rollers for nicks and scratches. The
rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.
7. Inspect the roll cage assembly for cracks or
excessive wear. If damaged, replace the roll cage
assembly.

FRONT GEARCASE REMOVAL

1. Place the transmission in Park. Elevate front of
vehicle and safely support machine under the frame.
CAUTION
Serious injury may result if machine tips or falls.Be sure
machine is secure before beginningthis service
procedure.
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