Front Gearcase Diagnosis - Polaris 2007 Sportsman 500 EF Service Manual

2. Using a 3/32 hex wrench, turn the back-lash screw out 3-4
turns. Re-apply Loctite 262
threads.
3. Turn the screw in until it is lightly seated, then turn the
screw out 1/4 turn.
4. Set the gearcase upright. Rotate the input shaft at least 4
times. This ensures the ring gear completes one full
rotation.
5. If a tight spot is felt during rotation, loosen the backlash
screw another 1/8 turn. Perform the step 16 again. Repeat
this procedure until the pinion shaft rotates smoothly 4
times (1 revolution of ring gear).

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).
™
onto the bottom screw
NOTE: To test the gearcase coil resistance, use the
coil harness. The gearcase coil should measure
between 22.8 ohms and 25.2 ohms.
Front Gearcase Coil Resistance:
Ω
24
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 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.
Armature Plate
Check for Wear Bands
FINAL DRIVE
±10%
7.19
7