2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 174Get this manual
FINAL DRIVE Cover Bolts Torque 14 ftlbs(19 Nm) 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 4A band with an interrupted wear mark may indicate warped plate, which may cause intermittent operationSee Illustration 1Armature Plate
12Install new seals into the gearcase housing and gearcase housing cover
Check for wear bands
FRONT GEARCASE DIAGNOSIS
Symptom: AWD Will Not Engage1Check the gearcase coil resistanceTo test the gearcase coil resistance, use the coil harness (GreyBrownWhite)The gearcase coils should measure between 22.8 ohms and 25.2 ohms2Check the minimum battery voltage at the wire (GreyBrownWhite) that feeds the hub coil wireThere should be minimum of 11.80-12.0 Volts present for proper operationBad Condition (Wear from Coil On Armature Plate)