2002 Polaris Sportsman 500 4x4. I have gone over this system more times then I have ever wanted in my lifetime. I haven't had 4wd on this bike for more than a year maybe 2 now. Everything is in place and put together just like is suppose to. I know the electrical system works in perfect shape. The awd hub parts seem to perfect shape. I have come down to hub coil magentic to be the problem the omns resistance is about 25 omns. I have no idea how to replace them and to be positive it the problem please up me before is lose it.

 

Both coils should no be bad at the same time? Armature plates replaced? Axle nuts torqued to 12 foot pounds? Have you jacked up machine with all tires off ground and checked awd operation? Is strut casting where coil mounts rough/worn an any way?

 

i have brand new armature plates, axle nuts are torqued, its been jacked up and checked and never works. ive down all the troubleshooting in the manual and it all comes down to bad coils. If there was a way test it ive done it.

 

You mentioned resistance check,BUT is there 12 volts going to each coil? Gray and gray/white wires. Test with sharp pointed test light with awd switch on and in gear.

 

i will have to check again to be sure but im 90% sure it does have 12 volts or a little more when i checked it 3 months ago when I try to fix it.

 

the tolerance between the inner pole and outer pole has to be one thou of an inch or less.my right side drive was not working and i closed the tolerance to 0 by laying a plastic ruler across the two poles and found it to be three thou.now it still magnitized the armiture plate,just not enough to engage the hilliard...............

 

I believe its the magnet not being strong enough because when I have it disassembled and turn on awd on the armature plate is pulled to the magnet but i can still turn the plate and pull it back off very easily. does that seem right

 

like in my last post if there is excessive clearance between the inner pole and the outer pole the magnetic attraction will not be that strong.(thats what she said!) the reason could even be different cv joints.

 

When i said it had 12 volts at were the coil plugs in I was wrong my fault it only has 9 volts. The battery does have 12 volts