Polaris RANGER XP 1000 2018-2019, Service Manual

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7.16
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
AWD DIAGNOSIS
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:
21.6 - 26.4 Ω
2. Turn the ignition and AWD switches on and place
gear selector in High or Low gear. Check for
minimum battery voltage at the Gray and Brown/
White chassis wires that power the coil. A minimum
of 11 Vdc should be present.
3. If electrical tests are within specification, remove
gearcase (see
“Front Gearcase Removal”page
7.17 ) and inspect components.
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.
FINAL DRIVE