2005-2007 Polaris Ranger 500 service manual, Page 219Get this manual
FINAL DRIVE AWD Diagnosis
Symptom: AWD Will Not Engage1Check the gearcase coil resistanceTo test the gearcase coil resistanceTest between the GreyBrownWhite wiresThe gearcase coils should measure between 22.8 ohms and 25.2 ohmsPossible Wear Ring on Armature Plate
OK Condition
Front Gearcase Coil Resistance: 22.825.2 Ohms
2Check the minimum battery voltage at the GrayBrownWhite wires that feed the hub coil voltageThere should be minimum of 11.0-12.0 Volts present for proper operationBad Condition (Wear from coil on armature plate) 4Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase coverThe top of the coil should be seated below the U-shaped insertThe U-shaped insert controls the pole gapIf the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gapIf the pole gap increases the coil will not be strong enough to engage the AWD systemIf this is the cause order new Plate Cover AssemblyGearcase Cover 3Inspect the armature plate for consistent wear patternThere should one or two distinct wear 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 the following illustrations