Polaris SPORTSMAN 600 Service Manual page 187

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
ILL. 1
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.
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 (PN
3233952).
Gearcase Cover
Side Cutaway View of Centralized Hilliard Cover
5. Inspect the rollers in the roll cage for nics and
scratches. The rollers must slide up and down
and in and out freely within the roll cage sliding
surfaces.
FINAL DRIVE
Possible
Wear Ring on
Armature Plate
OK Condition
The U--shaped insert
Coil
U--shaped insert
7.15