2003 sportsman 700 twin. My AWD does not disengage when the switch is off. Any suggestions on how to fix or trouble shoot it?

 

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.

 

I am working on a 06 sportsman 700 efi and the front diff is giving me hell had just done a bearing job and seals now it does not lock in. Has 12v to diff and cage is not broken new armature plate also

 

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..

 

If I ohm it out what should it be

 

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

 

When I ohmed it i got 27

 

Miss read your post..Kinda borderline on the coil,but most tolerances are at least +/- 10% or so.My bet is still the roller cage since so many failed.