2007 Polaris Sportsman 700/800/800 X2 EFI Service Manual, Page 228Get this manual
FINAL DRIVE 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 Cover Plate AssemblyCutaway View of Gearcase Cover
Gearcase Installation
12To install gearcase, reverse removal proceduresUse new roll pin in front prop shaftTorque mounting bolts in skid plate to 30 ft.lbs(41 Nm)