Front Gearcase Diagnosis - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

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).
NOTE: To test the gearcase coil resistance, use
the AWD coil harness. The gearcase coil should
measure between 22.8 ohms and 25.2 ohms.
Front Gearcase Coil Resistance:
24 Ohms ±10%
2. Check the minimum battery voltage at the Grey &
Brown/White wires that feed the hub coil wires.
There should be a minimum of 11.80-12.0 Volts
present for proper operation.
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc
3. Inspect the armature plate for a consistent wear
4. Check to make sure the coil is seated in the U-
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
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 4. A band
with an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
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 Cover Plate Assembly.
FINAL DRIVE
7
7.25