1985-1995 Polaris ATV and Light Utility Hauler Service Manual, Page 191Get this manual
FINAL DRIVE SYSTEM SERVICE 1989 To Present Models Front Clutch Re-assembly
When servicing the all-wheel drive strut assembly (replacing seal sleeve or installing new coils) it is important that the inner and outer poles of the electrically engaged front drive system be properly adjustedAs the armature plate is engaged, it should contact the outer magnet pole (seal sleeve) and may contact the inner magnet poleAlso, the armature plate must be flat when placed on flat surfaceBent armature plates must be replacedIt is not unusual to see double wear ring on the armature plateTo check the gap between the inner and outer poles place straight edge on the outer pole so that it just intersects with the inner poleThis measurement should be checked in three different positions The three around the pole assembliesmeasurements must be within .001" (.025 mm) of each otherIf the gap is narrow the front drive system may not disengage, and if the gap is excessive, it may not engage at allNOTE: Erratic engagement can also be an electrical problem or low batteryBe sure to check the electrical circuits and battery when diagnosing hub engagement problemsThe outer magnet pole (seal sleeve) is adjustable by either tapping inward or placing small punch to the inside edges and tapping the outer pole (sleeve) outwardNot Unusual To See Two Wear Rings