2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 253Get this manual
FINAL DRIVE 2Using 332 hex wrench, turn the back-lash screw out 3-4 turnsRe-apply Loctite 262 onto the bottom screw threadsNOTE: To test the gearcase coil resistance, use the coil harnessThe gearcase coil should measure between 22.8 ohms and 25.2 ohms
Turn the screw in until it is lightly seated, then turn the screw out 14 turnSet the gearcase uprightRotate the input shaft at least timesThis ensures the ring gear completes one full rotation
Front Gearcase Coil Resistance: 24 10
2Check the minimum battery voltage at the GreyBrown White wires that feed the hub coil wiresThere should be minimum of 11.80-12.0 Volts present for proper operation
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc 3Inspect the armature plate for consistent wear patternThere should be 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 operationIf tight spot is felt during rotation, loosen the backlash screw another 18 turnPerform the step 16 againRepeat this procedure until the pinion shaft rotates smoothly times (1 revolution of ring gear)