2010 Polaris Sportsman 850 Service Manual, Page 224Get this manual
FINAL DRIVE AWD Diagnosis
Symptom: AWD Will Not Engage 1Check the gearcase AWD coil resistanceMeasure between the Grey (C) and BrownWhite (B) wiresThe resistance value should be within specificationArmature Plate
Check for Wear Bands 5Check to make sure the AWD 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 insertIf 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 assemblyGearcase Cover Plate Asm
Front Gearcase Coil Resistance: AWD (Pin to Pin C): 24 ADC (Pin to Pin D: 12
Cutaway View 2Turn on the ignition switch and AWD switch and place gear selector in High or Low gearCheck for minimum battery voltage at the chassis-side of the AWDADC connectorMeasure between the Gray (C) and BrownWhite (C) chassis wires that power the AWD coilA minimum of 11 Vdc should be presentIf electrical tests are within specification, remove the front gearcase (see "Gearcase Removal") and inspect the internal 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 operationRoll Cage Assembly