That would be 24-28ohms is normal (seems to be the concensus). Zero ohms means you have a short in the wiring or coil somewhere. Infinite resistance means open coil or wiring. Let us know what you find.
Bryce

 

well in an automatic trans sometime a sprag will hang up a little when the outer or inner races are worn a bit
I would try a fluid change first when experiencing a sticking hub

 

I did find a pair of broken wires to the left front coil. After checking continuity to the remaining sections of wire I spliced them. If I check the brown to grey raedings without unplugging them from the connection box I get 13.1 ohms. If I pull them and test them individully I get 26.2 ohms. My guess is that with both coils in parallel like that the resistance decreases, eg. more wire to flow through equals less resistance. Unfortunately the front wheels still doesn't seem to be engaging. My friend who has an '87 trailboss says it would be very noticable if they were. So now do I tear in to the hubs and wash them out? Can the inner hubs be that worn? Other ideas? Thanks again.

 

Now that you have verified the coils and fixed the broken wires, which incidently guarantees that something would not work. Next thing to do is verify you are getting 12volts at the front coils when the AWD switch is on and the quad is running.
Bryce

 

Salmon
You stated before that you had the machine up on jacks, so now if I were you I would place the machine up in the air and

1. Place the shifter in low gear and turn off the AWD switch. Now start it and you should have both rear wheels rotating forward. Take a look at the drive shaft that turns the front hub it should be turning also as well as both front drive axles. You may see the tires turning in the front, but if you put your hand on them they should be easy to stop. If all this is turning move to the next step.

2. While the machine is still running turn on the AWD switch and observe the front tires they should BOTH start to turn and when you put your hand on them you should
Not be able to stop them.
Now hopefully it’s just one of the wheels that don’t engage but if it’s both then you have to confirm that you have power to the hubs through the switch. If you have power to the switch and to the hubs then

3. Disassemble the hubs inspect the rear seal for leakage and carefully inspect the roller cage and rollers for any chips or pitting also the shaft and bearings. If you find that everything looks good when disassembled move on to

4. Turn the key on (don’t start) and make sure the AWD SWITCH IS ON and take the armature plate and see if it sticks and is magnetized to the coil. You will be able to tell as it is a fairly strong attraction, turn the switch off and the plate should release.

Once you get this far you will have a lot better understanding of how this system works and you can post your findings and all of us will help you from there.

Take your time and CLEAN EVERYTHING these hubs hate dirt!

 

Wow, I just sorta cleaned my hubs on the 94 and everything worked! Does anyone know what the little steel cover/clip thing that fits over a steel cylinder in Front Diff of a 2004 700Sp does?. Its about one inch long and painted red in mine. Also has a little allen head bolt that the cylinder fits on,the bolt runs to outside the Diff case. Does this set the front gear lash?

 

Where are you guys getting the imfo that the gear ratio is different from front to rear. Because there is no gearing difference on a 2002-2006.

 

LOL.. They all have a gear ratio difference including the 2002-2006. Otherwise the front end would virtually always be locked up!! This is a basic concept that governs how the Polaris AWD works. [img]i/expressions/face-icon-small-smile.gif[/img]
Bryce

BTW.. Put your quad on blocks and count the revolutions front and back. You will see it.

 

I will ask the question once again...... WHERE DID YOU GET THE IMFO THAT THE GEAR RATIO IS DIFFERENT? Just for ***** ands giggles, I emailed a man I went to engineering school with who currently works at polaris. He to quote you "LOL" at the though that you think there is a gearing difference. SO ONCE AGAIN, WHERE DID YOU GET THAT IMFO?

 

I looked it up in the Polaris parts manuals. I have now done this for about 4 Polaris quads. Two of them are listed in this forum. Here is one Calculation And I wouldn't mention your Polaris engineer friend's name. He sure would have mud on his face!!
Bryce