I have a 2005 Sportsman 700 and I'm having AWD issues. AWD would engage and disengage with no problems other than AWD icon on cluster would flicker with the switch on and even off.

Pulled front gear box out and noticed that the person who owned this wheeler before me connected a ground wire to the brown and white wire going to the cover plate.

I removed the ground wire and connected the wiring back like new. I still have the gear box apart and when I connect just the cover up to the atv and flip the AWD switch the icon on the cluster works correct but the coil is not magnitizing. I can apply 12V to the cover from a battery and the coil will magnitize.

I checked the plug coming from the cluster and it is putting out 12V without the clutch cover installed whenever I switch the AWD switch on and 0V when I flip the AWD switch off as it should. With the cover hooked up to the atv, it's reading 12V at the connector but on the other side at the clutch plate it's reading around .225V.

I can hook the gray wire up to the connector on the atv and just ground the brown/white wire on the cover to the frame and it works without the AWD icon not working on the cluster.

I have ordered new armature, cage, rollers and seals from John Deere.

I apologize for being so long, just trying to provide enough information so someone has a clue as to what I'm dealing with. Thanks for any help!

 

Sounds like ground problem in the coil assy wiring either at the switch or in the coil itself and the previous owner tried to tie another ground into it to complete the circuit? I would ohm out the ground wire from the switch to the gear case connector and also the ground(brown/white) going to the coil. May need to replace the coil assy when you replace the cage and rollers. At least you should be able to check a little better when you strip it down. OPT

 

Thanks for the help Old Polaris Tech! I do have the gearbox apart and every thing looks good inside. When I got home from work today I ohmed out the wires going to the switch and they checked good. I tried to ohm the brown/white wire by using the case cover as a ground and it showed open.

I have just been hooking the case cover up to the wheeler and engaging the AWD switch to see if the coil will magnitize while trying to turn the armature by hand and still having no luck.

Is the coil grounded inside the case cover itself, and if so, is there a way to test it?

When I started all this, the gray and brown/white wire was ohming at 26.2 and know it's at 27.1. I'm leaning toward the coil being bad but want to be certain before spending $300.00.

What has me confused is that the coil will magnitize when I hook it directly to a battery, but I guess that's because I'm hooking one of the wires directly to ground and not going back to the speedo.

Is there anywhere besides polaris to buy this coil for a better price? Thanks!

 

I've replaced coils before because of shorts either in the grey or brown/white ground wire in the coil itself. Still sounds like this to me. I know there are probably different ways to maybe "rigg it",but its up to you?? Either spend the $ or do as the previous owner did. Don't know of any other source to buy the coil? OPT

 

Ok thanks again. Being an aircraft mechanic, I hate to "rigg" anything, which is a good thing I guess. Looks like I will be getting another coil.

 

Well, I believe I might have figured out what my problem is. I checked all wiring and it checks good. I think it's gonna be the ECM. The manual does say it provides power to the awd coil and a whole bunch of other things. My wheeler is an 05 model and that is the year they replaced alot of these. Unfortunally mine was not on the recall list.

I ordered a ECM and hopefully that's my fix. Whenever I replace it, I will follow up as to let everyone know if it works.