2009-2010 Polaris RZR Factory Service Manual, Page 242Get this manual
FINAL DRIVE AWD Diagnosis
Symptom: AWD Will Not Engage 1Check the gearcase coil resistanceTo test the coil resistance, measure between the Grey and BrownWhite wiresThe measurement should be within specification5Check 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 found, replace the cover plate assembly
Front Gearcase Coil Resistance: 21.626.4 Ohms
62Turn the ignition and AWD switches on and place gear selector in High or Low gearCheck for minimum battery voltage at the Gray and BrownWhite chassis wires that power the coilA minimum of 11 Vdc should be presentIf electrical tests are within specification, remove gearcase (see "Gearcase Removal") and inspect componentsInspect 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 5A wear band with an interrupted wear mark may indicate warped plate, which may cause intermittent operationSee the following illustrations: