Polaris 2012 Sportsman Forest 500 International, Service Manual

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7.15
FINAL DRIVE
7
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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.
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.
Armature Plate
Check for Wear Bands
U-Shaped Insert
Coil
Cutaway View of Gearcase Cover
Rollers