awd not disengaging
#2
I you haven't changed fluid in a while do this first. This may help. If it doesn't then could be as simple as a magnetized armature plate keeping the awd locked in or a cracked plastic roller cage which was another common thing to happen. Either way if you have to split the front diff,go to an aluminum roller cage and new armature plate and hopefully no more problems.Plenty of these on ebay,amazon,etc.
#3
#4
If it has voltage to the coil,several things could be happening. Coil internal wiring may be bad not being able to grab the armature plate,the armature plate itself may be warped or worn not allowing engagement,plus people do over look hairline cracks in the plastic roller cages. I've almost missed a couple on this myself. Only other things are the out put hubs but not normal for them both to strip splines or have problems at the same time. Over looked the new armature plate you listed..
Last edited by old polaris tech; 01-18-2017 at 04:10 PM. Reason: new armature plate
#6
22.8-25.2 ohms from my 2005 manual. Would guess the 06 is the same. If you want to double check or need a good manual,here's one for 5 bucks.2006 Polaris Sportsman 700 EFI Service Manual PDF Download
#7
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#8