Polaris RZR XP 1000, Service Manual

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7.32
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 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
1
(GY)
and ground wire
2
(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 (see Chapter 7 –
Front Gearcase
Removal, page 7.33) and inspect components.
4. Inspect armature plate
3
for a consistent wear
pattern. There should be two distinct wear bands
4
.
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
5
is seated in the U-
shaped
6
insert that is pressed into the gearcase
cover
7
. 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.
FINAL DRIVE