Polaris 2005 Sportsman MV7, Service Manual

Page: 202 / 312

FINAL DRIVE
7.16
19. If a tight spot is felt during rotation, loosen the
backlash screw another 1/8 turn. Perform the
previous step 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). The gearcase coils should
measure between 22.8 ohms and 25.2 ohms .
2. Check the minimum battery voltage at the wire
(Grey & Brown/White) that feeds the hub coil wire.
There should be a minimum of 11.80--12.0 Volts
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
Possible
Wear Ring on
Armature Plate
OK Condition
Bad Condition
(Wear from Coil
On Armature Plate)
ILL. 1
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. 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