7.20
FINAL DRIVE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Front Gearcase Diagnosis
• Symptom: AWD Will Not Engage
1. Check the gearcase coil resis
tance. To test the
gearcase coil resistance, use the coil harness (Grey
& Brown/White).
NOTE: To test the gearcase coil resistance, use the
AWD c
oil harness. The gearcase coil should
measure between 22.8 ohms and 25.2 ohms.
2. Check the minimum battery voltage at the Grey &
Br
own/White wires that feed the hub coil wires. There
should be a minimum of
11.80-12.0 Volts present for
proper operation.
3. Inspect the armature plate for a consistent wear
patter
n. 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.
4. Check to make sure the coil is seated in the U-
sh
aped 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.
Front Gearcase Coil Resistance:
24 ±10%
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc
Armature Plate
Check for Wear Bands
U-Shaped Insert
Coil
Cutaway View of Gearcase Cover
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