2005 Polaris Sportsman 700/800 EFI Service Manual, Page 202Get this manual
FINAL DRIVE 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
19If tight spot is felt during rotation, loosen the backlash screw another 18 turnPerform the previous step againRepeat this procedure until the pinion shaft rotates smoothly times (1 revolution of ring gear)
Check for wear bands ILL1 Possible Wear Ring on Armature Plate
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 operation