7.20
FINAL DRIVE
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
AWD Diagnosis
Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the coil
resistance, measure between Grey and Brown/White
wires. Measurement should be within specification.
2. Turn on ignition and AWD switches and place gear
selector in High or Low. Check for minimum battery
voltage at Gray and Brown/White chassis wires that
power the coil. Should have a minimum of 11 Vdc.
3. If electrical tests are within specification, remove
gearcase (see “Gearcase Removal”) and inspect
components.
4. Inspect armature plate for a consistent wear pattern.
There 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 5. A wear band with
an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
5. Check to make sure the coil is seated in the U-shaped
insert that is pressed into the gearcase cover. The top
of the coil should be seated below the U-shaped
insert. The U-shaped insert controls the pole gap. If
the top of the coil is above the surface of the U-shaped
insert it raises the armature plate, thereby increasing
pole gap. If the pole gap increases the coil will not be
strong enough to engage the AWD system. If this is
found, replace the cover plate assembly.
6. Inspect the rollers for nicks and scratches. The rollers
must slide up, down, in and out freely within the roll
cage sliding surfaces and H-springs.
7. Inspect the roll cage assembly for cracks or excessive
wear. If damaged, replace the roll cage assembly.
Front Gearcase Coil Resistance:
21.6 - 26.4 Ohms
Check for
Armature Plate
wear bands
Gearcase Cover Plate Asm.
Coil
U-shaped insert
Side cutaway
view of cover
Rollers
Roll Cage Assembly
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