Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 248 / 406

7.20
FINAL DRIVE
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 Cover Plate
Assembly.
5. Inspect the rollers for nicks, scratches, and flat spots. Also
inspect the roll cage for cracks and ensure the rollers are
able to slide up and down and in and out freely within the
roll cage sliding surfaces.
Gearcase Installation
1. To install gearcase, reverse removal procedures. Use new
roll pin in front prop shaft.
2. Torque mounting bolts in skid plate to 30 ft.lbs. (41 Nm) .
3. Add the proper lubricant to the front gearcase. Check drain
plug for proper torque. Refer to Chapter 2 for fluid fill and
change information.
U-Shaped Insert
Coil
Cutaway View of Gearcase Cover
Rollers
= T
Gearcase Mounting Bolt Torque:
30ft.lbs. (41 Nm)
30ft.lbs. (41 Nm)
New Roll Pin