9929375 R02 - 2016-2019
GENERAL
/
GENERAL 4
Service Manual
© Copyright Polaris Industries Inc.
7.57
TROUBLESHOOTING - FINAL DRIVE
FINAL DRIVE TROUBLESHOOTING
Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the coil
resistance, measure between the power wire
q
(GY)
and ground wire
w
(BN/WH). Measurement should
be within specification.
Front Gearcase Coil Resistance:
21 - 27 Ω
2. Turn on ignition and AWD switches and place gear
selector in High or Low. Check for minimum battery
voltage at Gray and Brown/White chassis wires that
power the coil. Should have a minimum of 11 Vdc.
3. If electrical tests are within specification, remove
gearcase and inspect components. Refer to
procedure.
4. Inspect armature plate
e
for a consistent wear
pattern. There should be two distinct wear bands
r
.
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 5. A wear band with an interrupted
wear mark may indicate a warped plate, which may
cause intermittent operation.
5. Check to make sure the coil
t
is seated in the U-
shaped
y
insert that is pressed into the gearcase
cover
u
. 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 found, replace the cover plate
assembly.
6. Inspect the roller surface on the inside of the ring gear
for gouging/rough spots.
7. Inspect the roll cage
o
assembly for cracks or
excessive wear. If damaged, replace the roll cage
assembly.
8. Inspect the rollers
a
for nicks and scratches. The
rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.
